Hello.

tk11b40 wrote:

... Bigger pictures are possible.... All the good comments help....

Am not a machinist, so don't do well with Half-size pictures. :lol:

Just joshing with the unhelpful-not-so-good comment before echoing:

WELCOME tk11b40 ! We're glad you're here!

Ok

Well it's been awhile since I posted on the forum.

The bike has ad the frame powder coated, i got the rear brake all machined up to fit the CR caliper.

Found a set of ohlins shocks.

Started it up ran it awhile, then tore it all down..end of "Mock Up stage".

Purchased a new wiring harness, that goes in next.

Pictures..

Motor in frame for the last time....

ok image too big

motor in frame for the last time II

I have dropped a few engines into KZ frames in the past, so this time a took a different approach in order to avoid the scratching fo the frame problem.

Removed the Clutch cover, then drilled the bolt pattern into a dirt bike stand. Bolted through the stand into the case (clutch cover holes) on the stand vertically.

now the engine is oriented verticle.

Soooo instead of muscling a giant motor horizontal like, we just eased the frame over the engine, bolted the engine in, and flipped the frame to it's regular world (motor horizontal), and removed the dirtbike stand from the engine. The whole process was much easier, and not a scratch on the frame.

Here is a photo of the engine mounted on the stand.

The frame has undergone quite a bit of surgery.

First we bought the Kosman gusset kit, Tig welded it in. Cool huh? That was about two years ago. So I get it powder coated the "first" time (this is the second powder coating), bring it home all smileyB) when we realizes that the ZRX Swingarm will need larger bushings, I had to have that swingarm. So as I said before machine some alignment stuff, and cut out the old bushings, and welded in new ones.

Powdercoat 1 is toast.

We are then looking at the spindly rear section of the frame and realizing the new swingarm is much stiffer than the rear section. More Gussets, and boxing in the rear section.

Ok resize image and post..

These photo's are kind of out of order, but here is what it looked like at the final mock up. I started it a few times, satisfied all was well had to tear it down for the final frame powder coating.

Lots and lots of work.

The Engine Polishing campaign..

You know people ask me how many hours are into the engine polishing....

Well, I dunno. when I am sitting around the house I go out and look at the engine, and go Dam theres another spot I could get to with a thinga ma jig mounted to a toothbrush, and yea two hours later I have done a few square inches.

It's been like that for a few years...so I kinda think about 100-200 hours.

So there is no order to the photo stuff..

This is a front view of the modifications prior to brazing on the steering stops, and powdercoating the second time.

Ok

Well the welcome thread is for introducing ourselves, so I ahve definately overcooked my share of that space.

In the coming weeks I hope to organize this a little better and try to post it as a seperate topic.

I want to be a help to those who are trying the same thing.

I look forward to having all my questions answered and hopefully answering a few myself.

tk11b40....