Testarossa's 78 KZ1000 Fighter Build

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19 Apr 2010 17:28 - 19 Apr 2010 17:38 #361782 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

You aren't kidding about that baffle being thin sheetmetal. I'm guessing that it's 24ga. As soon as the arc would stabilize I would start to burn a hole. I resorted to using loads of small tack welds. I bet I put 150 tacks on that thing. Next time I'm gonna make a new baffle from scratch.

Mark, I'm kicking myself for not knurling those footpegs before I welded them up. Knurling steel takes a lot of tool pressure, and it helps to have a sacrificial section to chuck on that will be cut off. I'm not sure how I'll handle it yet.


u are so narrow minded young man.
i see 2 obvious, options. i can lend u my trusty grinder, or u can continue your tack welding foray, and tack some lumps on there.
:P

those pegs just might work. dif , but that doesnt mean bad.its worth a look if u like them. can u add more knurl the rest of the way across?

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
Last edit: 19 Apr 2010 17:38 by mark1122.

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19 Apr 2010 17:49 #361783 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Mark, I'm satisfied with my lumps, thank you. Plus, I wouldn't want you to go without ole Betsy!

As for adding the knurling, it is difficult to match up knurls. Best done in one continuous pass.

BTW I have a trusty grinder of my own. It has held up for nearly 15 yrs. Don't forget that I am on Team Grinder.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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19 Apr 2010 21:14 #361818 by porchev914
Replied by porchev914 on topic Testarossa's 78 KZ1000 Fighter Build
You may be stuck with knurling a new piece of tubing for the pegs, then cutting off and rewelding the peg mounts on the knurled tubing. As for the freestyle pegs, I can just see you pulling a no handed backflip with those things :P I would suggest you throw 'em on just to see, but that is more fab work that you don't need. The exhaust looks nice and clean..I'm still jelous you have an exhaust!

FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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19 Apr 2010 21:14 #361819 by Tony
Replied by Tony on topic Testarossa's 78 KZ1000 Fighter Build
Way to go on welding that baffle. It looks good. I just got a bottle for my mig welder and am itching to try it out.

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20 Apr 2010 04:39 #361843 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
porchev914 wrote:

You may be stuck with knurling a new piece of tubing for the pegs, then cutting off and rewelding the peg mounts on the knurled tubing. As for the freestyle pegs, I can just see you pulling a no handed backflip with those things :P I would suggest you throw 'em on just to see, but that is more fab work that you don't need. The exhaust looks nice and clean..I'm still jelous you have an exhaust!


I got most of my scars trying freestyle tricks when I was a lad. I guess that's why I am a bit more cautious these days. I don't heal so fast anymore. I'm gonna punt on the footpegs for now. Bigger fish to fry.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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20 Apr 2010 04:42 #361844 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Tony wrote:

Way to go on welding that baffle. It looks good. I just got a bottle for my mig welder and am itching to try it out.


First MIG welder? It's addictive! Get an auto-darkening helmet if you don't already have one. They seem expensive until you use one. Worth every penny.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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20 Apr 2010 04:53 #361849 by T_Dub
Replied by T_Dub on topic Testarossa's 78 KZ1000 Fighter Build
x2 on the auto darkening. It's amazing the first time you use one.

1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler

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20 Apr 2010 05:19 #361855 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

BTW I have a trusty grinder of my own. It has held up for nearly 15 yrs. Don't forget that I am on Team Grinder.


:laugh: :laugh: Thats funny Josh.and u have the scars to prove it.;)

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

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20 Apr 2010 07:32 #361877 by Tony
Replied by Tony on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Tony wrote:

Way to go on welding that baffle. It looks good. I just got a bottle for my mig welder and am itching to try it out.


First MIG welder? It's addictive! Get an auto-darkening helmet if you don't already have one. They seem expensive until you use one. Worth every penny.



This is my first mig welder. I bought the auto darkening helmet a couple of months before I bought the mig welder. :laugh:

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20 Apr 2010 13:45 #361983 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Have you used the welder with flux core before you got the bottle?

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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20 Apr 2010 14:58 #361998 by porchev914
Replied by porchev914 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Have you used the welder with flux core before you got the bottle?

Gotta love the flux core! :whistle:

FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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20 Apr 2010 20:25 #362061 by Tony
Replied by Tony on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Have you used the welder with flux core before you got the bottle?

I used it to do a couple of small project. The splatter was pretty bad. I was welding some thin stuff and did the same as you did by doing a bunch of very short welds.

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