Finely Started, KZ1300 INTERCEPTOR "Pictures as available"

Pyxen
I do a lot of Glas,Plastic and Carbon work. Nothing is HARD only time consuming. If you choose the correct material to work with, everything will look like it came that way from the factory. The mounting bracket idea for the side covers is the best one unless you choose to cut and weld. That would be only a last resort. The trick to body work is in, first removing ALL the paint in the areas where you plan on adding material. Second thing is to reshape as much as you can with heat. Always use a heatgun and never a torch. Reweld as much of the plastic peaces as you can useing Methaline Chloryde. Next thing is to lay out everything in cardboard and tape. You may also use C.A. (super glue)to mount the cardboard, if tape is not convenient. Than lay all of your Glass and filler over the cardboard. Never use bondo for the main shaping material. There are a number of products made by"Evercoat" which are made for building on plastic. Once you have placed on the first structural layers of Glass and filler, remove all the cardboard with water and a brush. Now you can finish laying up the rest of the glass and filler as desired. Rember one thing, If it is easy to sand than it is not good for the main shape and structure. Everything you see on the fairing has only been sanded with 50 and 80 grit paper, that is how tough the filler I used is. There will not be any external bondo on the fairing at all. The last step will be a coat of "Featherfill" than a thin coat of epoxy primer than paint. I should have some more pictures on Saturday. By the way, I have since the last picture, filled in the Mirror mounting "Tumer" and will mount the mirror on a smooth surface and not in that recess.

Otto K.

that's a lot of good tips..thanks!

This is the thread I've started about it with some pics..I'm going to be posting a new pic today. I've mod podged the foam form I made to give it a solid shell, and now I'm ready to do something with glass, but I don't know how to start exactly.. well it's all in there anyways.

kzrider.com/component/option,com_joomlab.../id,105611/catid,11/

Input would be greatly appreciated.

Hi Pyxen
Are you useing any part of the oryginal KZ tail piece in the underlying structure in your foam? Also, You must use a Chemical impervious foam in your carved prototype. In this way you can use any type of lay-up materyal on top and save yourself a lot of work later.

Otto

Nope - it's 100% original.

Does adding a layer of modpodge/paper between the resin and foam change the type of foam I would need?

The stuff I used is very basic styrofoam insulation..the kind that breaks apart into small balls.

Thanks Otto - looking forward to more pics of your project!

Post edited by: pyxen, at: 2007/01/26 08:02

Pixen

What you want to use is what is known as "Proto-Foam" It is a Urethan based foam with a filler. It carvs to perfect shapes and it is impervious to ester based fillers, which are, what you will use to build the final surface of your tail. The foam is expensive but worth every Penny There are different densities of this foam and it is made expresly for carving intricuit shapes, and detail. The foam you used will be a nightmare to get into a good smooth shape and you will have to use Epoxy to do it with. Epoxy is very good but it takes too l;ong for each layer to harden and it is EXTREMLY expensive and hard to sand.

Otto Kudrna

I have had some questions on How To when it coms to FG and composite work. I will start a new thread in the technical forums with a lot of pictures. My Fearing is almost finished and I took pictures of the entyre process. I will post a link here when I start the article. I have also picked up some 66mm Pistons for this beast and am in the proces of having some custom sleaves made. This will make the bike a 1500.

Otto Kudrna

1500?? That's awesome

Looking forward to the new thread and pics of your fairing for sure..!

any updates?

No updates at the moment. right now I am concentrating on my GPZ1100 (1150)
You can see it in this link here. I should be finished with the GPz erly this spring and than I will go full tilt on the 1300.
kzrider.com/component/option,com_joomlab.../catid,11/id,169462/

It has been quite a while since I have made any updates here. I glanced threw the stuff I have posted in the past and have already made some changes. One major change is the ignition. I will be useing the Nology mini coils, which I have bought quite a while ago. they are about 2.8 Ohms and will fit in the oryginal spot. the front end will be replaced with ZN1200 front fork set that do not thave the leading axle. I have a set of custom cams that I had made for me and will be useing a 85 ZN1300 head with the larger valves. My cylinders have already been bored to 1400 and are ready to install.

So are you getting back to work on the 1300 now? I'd be interested in seeing some more progress on this one. I'm a big fan of the 6 cylinder bikes. If it turns out as well as your GPZ1150, it should be a stunner.

wow, you have another cool bike! this will be good!