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Deacon's 1978 KZ650 Cafe Project 05 Oct 2008 15:59 #240282

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Deacon's 1978 KZ650 Cafe Project 05 Oct 2008 16:01 #240283

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Deacon's 1978 KZ650 Cafe Project 05 Oct 2008 16:04 #240285

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I don't have a close up, but here is a pic of the dent in the muffler. There is an almost identical one on the other side.

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Deacon's 1978 KZ650 Cafe Project 05 Oct 2008 16:14 #240287

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To get rid of the horrible dents, I decided to shorten the two mufflers. I ended up cutting off around 7" off the end. I first removed the stock baffles from the ends and then cut the ends off. Since I don't have a welder I asked a good buddy of mine to weld the baffles back into the shortened mufflers. He did an amazing job.

I finished them off by scuffing up the chrome and painting with high temp black paint (which has held up really great all summer).

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Deacon's 1978 KZ650 Cafe Project 05 Oct 2008 16:21 #240291

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Since the headers were so ugly looking, I sanded off the rust as best I could and painted with high temp paint. I then wrapped them with black header wrap. I initially bought 50' thinking it would be enough. I ended up being short and had to buy another 50.

I can't find any pics of the wrapped headers or finished tails, so I guess you'll have to wait until the end of the project. :)

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Deacon's 1978 KZ650 Cafe Project 06 Oct 2008 18:28 #240459

  • Bad Kaw
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Cool...looking forward to more progress pics.
-KR
78 Kawasaki Z1R
81 Kawasaki KZ1000J (mods)
82 Kawasaki ELR Clone (1000 J)
82 Kawasaki KZ750R1/GPz750 ELR-ed
70 Kawasaki KV75
83 Honda CB1100F (few mods)
79 Suzuki GS1000 (rolling frame / project / junk)
84 Suzuki GS1150ES (modified project)
83 Yamaha XJ900R (project / junk)

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Deacon's 1978 KZ650 Cafe Project 06 Oct 2008 18:45 #240466

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Good stuff, HD. Looking forward to the next instalment of this story.

Best of success. :)
1977 KZ650-B1 (Stock)
Upgrades:
- Dyna S Electronic Ignition (DS2-2)
- Dyna 3 Ohm Coils (DC1-1)
- Coil Repowering Mod
- Progressive Springs Front & Rear
- Saddlemen Seat Cover
- New Metallic Red Re-Paint & Repro Badges.
Montreal, Canada

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