Testarossa's 78 KZ1000 Fighter Build

Now on to actual work on MY bike. I started cleaning up some of my welds on the frame braces. I'm not sure that I will grind all of the welds, but I do plan to do the visible stuff.

Looking good Josh. Are you using a flapper disk on your angle grinder? 120 grit?

Great job Josh. those welds look beauties.
i just wanted to mention that, had u used a 1 piece, u would need to fill the O ring galley with silicone.
the 2 pc head gasket is fine. but they are not available for bigger bores.

when i have to grind and metal prep welds i always dream of having a dynafile
pathon.com/dynafile.htm

one of these days i will have one tho, .bicycle frame builders use them to make the welds disappear.
your frame is looking good you are making some solid progress.

leon

Thanks fellas. Adam, I have used a variety of abrasives in those pictures. I started with an old worn down cutoff wheel in the angle grinder to knock down the high points of the welds. That helps to save sanding disks and flap wheels. Next I use a 60 grit flapwheel if I can get that to the weld. Then I have roloc disks for my die grinder in various grits to 120. I also have a drum sander kit that can be used in a drill which leaves a nice fillet radius if you can get it in the weld. I'll finish everything by sandblasting to give an even finish.

Leon, you are right to want an Dynafile. I used to use those every day at the last machine shop that I worked in. We used 'em to knock the burrs off of inconel, titanium, and waspalloy parts. They are expensive, but totally worth the price. All you ever have to do is give it a couple of drops of air tool oil and change a sanding belt periodically. We literally used them 23 hrs a day 6 days a week. If anything else could even come close to knocking down an inconel burr, then I would have used it. Those burrs are like pocket knife blades sometimes. I think that an insert salesman told me that inconel burrs can be up 62 rockwell, that's hard. Too bad they belonged to the company.

Here's another photobomb of my progress on smoothing welds. I have most of the welding finished on the frame. I think that I can see over the hill on the frame modifications now. Just a couple of beads left to clean up.















Adam, I discovered that it actually helps to use a 36 grit flapwheel after you grind the tops off the welds. I'm sure that I'll hate myself for that 36 grit later, but it sure works good for shaping steel.

frame looks good testa,should be stout as he!!.are you going to have passenger peg mounts?keep up the good work.

leon

i cheated and use bondo.
Nice job.

Leon, I'm still debating about the passenger footpegs. I want something removable, and not sure how I will handle it yet. I remember you showing me your passenger peg mounts before.

Mark, how is your bondo holding up in those welds? I'm scared of using too much filler. I would hate to have a chunk of filler pop out when the frame tries to flex. If anyone can make it flex it's gonna be me.

Beautiful work my friend, beautiful work. I Need to get some of those roloc discs but i haven't found a local supplier yet. Any suggestions? I'm planning on smoothing my frame just like you're doing to your so i appreciate the heads up on your step by step.

You can order them here: www1.mscdirect.com/CGI/GSDRVSM?PACACHE=000000150297154

Also check to see if you have a Fastenal store locally. I think that you have to have an account, but they usually stock them. You could see if there is a machine tool dealer locally. Anybody selling cutting tools would stock them. Don't buy the ones from the Borg, they're a ripoff.