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TOPIC: Another 81 GPZ. Losing the fat.

Another 81 GPZ. Losing the fat. 21 Jun 2008 09:38 #221350

  • loudhvx
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Next was the seat pan. It's 1/8" aluminum bent by hand on wooden forms. The rear bend was done without anything special, but the side edges were tougher. The trick on the side bends is on the underside. Before I bent it, I took a 1/4" thick grinding wheel and cut a groove along the bend line on the underside. I cut about 1/32" deep. This forced the bend to be straight, and it also controlled the bend nicely so there are actually 2 bends right next to each other if you look very carefully in person. This gave a very nice machine-bent look to it.

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Another 81 GPZ. Losing the fat. 21 Jun 2008 09:43 #221351

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Other angles with the headlights.







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Another 81 GPZ. Losing the fat. 21 Jun 2008 12:17 #221380

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What a great write up and very cool looking tail.B)
I know you plan on painting it but I must say the transparency is pretty wicked looking.:woohoo:

Any recomendations on what plastic to use for replacing the winshield? I have a heat gun so it is on my list of things to try.
s49.photobucket.com/albums/f255/JohNLA_photo/1983%20GPZ%20550/
83 GPZ 550 Stock with 3600 miles_83s.
83 GPZ 550 4-1,pods,Mikuni 36,000 + miles

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Another 81 GPZ. Losing the fat. 21 Jun 2008 13:56 #221394

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Wow Lou, where do you live?? Im movin next door! Great lookin, cant wait to see the results!
Lou, I was told you would be the guy to ask, would you have a spare throttle assembly laying around? I have kz550a3, missing the starter button. Was wondering if you even had a spare start BUTTON, or horn button?

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Another 81 GPZ. Losing the fat. 21 Jun 2008 16:06 #221409

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Your rear tire look larger than stock, are you running oversize, if so what size?

Ps. If you've got any more of those front Metzlers hanging around...
Rob A.
550 A4
GTA,
Ontario, Canada

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Another 81 GPZ. Losing the fat. 21 Jun 2008 18:10 #221414

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I used to use plexiglass a lot back when I made tack boxes for horse equipment. Something I did that you might consider for this project is to reverse paint the plexiglass. What I did was to paint the backside of the panels with auto paint. It works pretty slick because you can be a total hack with a spray gun and it will still look good. It is like having 1/8" of clearcoat on your paintjob. Just lightly wetsand the plexi to give the paint something to grab onto.
Andy
Akron, Ohio
80 Z-1 Classic-Sold
84 GPZ1100
79 KZ 1000 LTD
78 KZ 1000 A2
77 KZ 1000 LTD-Sold
76 KZ 900 The definition of a barn find
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Another 81 GPZ. Losing the fat. 22 Jun 2008 02:51 #221456

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violentvintagecycles wrote:

Wow Lou, where do you live?? Im movin next door! Great lookin, cant wait to see the results!
Lou, I was told you would be the guy to ask, would you have a spare throttle assembly laying around? I have kz550a3, missing the starter button. Was wondering if you even had a spare start BUTTON, or horn button?


I still have a spare button I made on this old thread:[url=
kzrider.com/index.php?option=com_kunena&...&catid=4#176638]Home made starter button[/url]

That thread has links on where to buy rplacement starter buttons too. Is it only the start button that is broken on the assembly? Then I would just rplace the button. If you want I could sell you the one I made, but I'm sure the other ones available are better.

oh, and Chicago.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 02:56 #221458

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JohNLA wrote:

What a great write up and very cool looking tail.B)
I know you plan on painting it but I must say the transparency is pretty wicked looking.:woohoo:

Any recomendations on what plastic to use for replacing the winshield? I have a heat gun so it is on my list of things to try.


Definitely polycarbonate AKA Lexan. Don't use acrylic. It will shatter if it gets hit with a rock. The Lexan will only scratch. Try your local home center, they should have sheets of the stuff in the windows and doors section. Plan on experimenting to get the knack. I bought acrylic to practice on since it's cheaper, but the final product should be Lexan. Also, I recommend mocking everything up in cardboard first.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:02 #221460

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Saki Jockey wrote:

Your rear tire look larger than stock, are you running oversize, if so what size?

Ps. If you've got any more of those front Metzlers hanging around...


I'll give you the front Metzler, heck I'll give you two of them, but they are old, worn, and starting to get tiny cracks. I am going to get a new Dunlop GT501 front before I do any serious riding.

I think the rear is close to stock but it looks bigger for some reason in the photos. It's probably the camera angle plus the wheels are painted black which creates an illusion.
I think it's supposed to take a 120-90-18". But I have other gpz550's with 130-80-18". The wider 130 slips less on acceleration, but is less stable than the narrow 120 in turns. I haven't decided which I like better, but the 130 does look cooler.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:12 #221461

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The Gringo wrote:

I used to use plexiglass a lot back when I made tack boxes for horse equipment. Something I did that you might consider for this project is to reverse paint the plexiglass. What I did was to paint the backside of the panels with auto paint. It works pretty slick because you can be a total hack with a spray gun and it will still look good. It is like having 1/8" of clearcoat on your paintjob. Just lightly wetsand the plexi to give the paint something to grab onto.


Yeah I played with that idea on an acrylic test piece. It looked very cool. I didn't even sand the acrylic and I could not scratch the paint off. I purposely shattered the acrylic to see if any paint would flake off. Not a single flake of paint came off. The paint was about 1 week old at the time. I wonder if would have flaked off after hardening for a few years.

I haven't painted the Lexan yet, but that backside idea is out of the question. The Lexan, being much softer, scuffed a lot during the fabrication. It actually has a light imprint of wood from the bender, so it has to be sanded. I'm going to leave it clear for awhile just for the novelty. I'm thinking of putting a green fluorecscent lighting tube in the tail to light it up.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:14 #221462

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Here's a shot showing the brake reservoir bracket.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:17 #221463

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Here's a shot with the tail and seat assembled, but not painted yet.
(Kz400 in the background. Will post a thread on that later.)

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:22 #221464

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and here's all of the electronics stuffed under the seat. I really had to work to retain the hinge-ability using the stock latch and prop-rod. I used the battery box mount as the hinge mount. This allowed me to make the seat about 2 inches narrower. The seat is supported in six locations. I wired the whole bike in about 3 hours so it looks a little messy. But with the seat down, everything is out of sight.

The black capacitor is a spare in case the blue one blows up. I have two fuse holders tucked in there as well. 20 amp main and a 5 amp just for the capacitor in case it shorts out. I also have a detector to tell if the capcitor stops capacitating, but it isn't mounted yet. The small black block is the ignitor.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 03:28 #221465

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Those indoor shots suck. I'll reshoot them outside when I get a chance. Plus my buddies KZ400 in the background needs some major cleaning.

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Another 81 GPZ. Losing the fat. 22 Jun 2008 13:52 #221531

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I really admire your work, Lou. You're an inspiration for a lot of us out here in KZ Land...
1980 KZ750-H1 (slightly altered)
1987 KZ1000-P6 "Ponch"
1979 GS1000 "Dadzuki"

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Another 81 GPZ. Losing the fat. 22 Jun 2008 19:54 #221595

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Thanks a lot Justin! :)

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Another 81 GPZ. Losing the fat. 23 Jun 2008 06:46 #221653

  • BeeSting
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The pic of your electronic setup is just sexy. If you can post more pics that would be great.
BeeSting

Flint, Michigan - Chicagoland, IL

If I wasnt such a badass American, I would have to drive a Harley to make up for it

1980 Kawasaki KZ750 H1 LTD (4)
Kurayami (Girl of Darkness)暗闇の女

1980 Honda CX500C - GONE
Christine

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Another 81 GPZ. Losing the fat. 23 Jun 2008 09:52 #221675

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Lou, You are a fabricating master!

I can't wait to see it all done:)
Tom
Holland, MI

1980 KZ550 ELR


1987 ZL1000 Eliminator

1973 350 triple

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Another 81 GPZ. Losing the fat. 23 Jun 2008 11:01 #221686

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Lou,

i believe the name of that bike should be the "invisible jet" and you will need a tiara.:P It looks awesome!!!!

Hey i saw your yellow bike at mods vs rockers but didnt see you there.
1977 KZ1000A1, 1979 KZ650 C3

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Another 81 GPZ. Losing the fat. 24 Jun 2008 07:11 #221819

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galaxian wrote:

Lou,

i believe the name of that bike should be the "invisible jet" and you will need a tiara.:P It looks awesome!!!!

Hey i saw your yellow bike at mods vs rockers but didnt see you there.


Yeah, my buddies and I were hiding in the 7-11 lot. Nice day. It wasn't as Harley crowded like last year.

I was hoping to get the invisible jet ready for mods v rockers, but it was about a week behind schedule... and the tiara was at the jewelers for sizing.

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