76 KZ900 B1 - from crates.

...then spend a ridiculous amount of time trying to get the angle with the fish-mouthing jig, (before realizing using an plain-old angle grinder is simpler and faster). Then of course I would have not had the pleasure of creating this piece of jigging...

photo for above post.

With the purchase of ZX 636 rear wheel, I figured it was time for a mock-up.

better light

And with tank and cardboard template for the seat.

Been working on those subframe stays for a while now as getting them to fit nicely has proved pretty time consuming, but I'm nearly there. I'll post when I weld 'em in.

Trick parts take time to make. I know I have a sizable pile of tubing and such that have incorrect lengths, bends, notches orientations. It's the price I pay for learning a hobby :silly:

Nice looking project Rob.

You might try looking for a zx-10r front wheel as well. The front wheel on mine looks the same as those zx-6r wheels. It might broaden your search a little.

I am dying to know how you got that tube to bend around a wooden form so cleanly. What wall thickness is that tube that you used. How long was the tube that you were pulling on?

BTW, who's the cyclist in the family? I spy a Park Tool Crank puller on your pegboard. :dry:

Nice bike I am plannin a similar build to my kz 700 def gona subscribe

testarossa wrote:

I am dying to know how you got that tube to bend around a wooden form so cleanly. What wall thickness is that tube that you used. How long was the tube that you were pulling on?

BTW, who's the cyclist in the family? I spy a Park Tool Crank puller on your pegboard. :dry:

The tubing is about 1/10" thick (measured with a micrometer, not sure if I found a low spot and it's supposed to be 1/8"). Still pretty new to metal sizing.

I actually bent three bars. The first one I heated (with propane), and the second two without. There was a difference, but not a huge one. Perhaps oxy-acetylene would have made a bigger difference, as propane doesn't really get terribly hot. The bars were about 5' long and I have another 2' piece (of larger diameter) tubing I used for leverage. I would have liked to go longer, but the setup in the shop didn't allow for it.

The jig was made from 2 pieces of 7/8" MDF (clamped and glued together), jog-sawed and sanded to shape. I then used a router to cut a pretty deep channel, which the tubing fit into very snugly.

Also, not sure if you can see all the lag-bolts in the jig (7), but that thing was very securely attached to a workbench. Te bench is in turn bolted into two ledger strips that are bolted into the studs of the garage wall. It's pretty stout.

I was reminded that I am not quite as stout as the bench when I tweaked something in my shoulder on one of the more aggressive heave-hos. :blink:

BTW - good spot. That is indeed a Park Tool Crank puller - been messing with bicycles since I could crawl

ready2ryde1985 wrote:

Nice bike I am plannin a similar build to my kz 700 def gona subscribe

Just recently became aware of the KZ700. It's a fairly rare beasty, no?

porchev914 wrote:

Trick parts take time to make. I know I have a sizable pile of tubing and such that have incorrect lengths, bends, notches orientations. It's the price I pay for learning a hobby :silly:

..yeah and a little flesh and blood. :lol: