On the rust you may want to just use a little oil on a fine plastic abrasive pad. If you use sandpaper or steel wool you will have to deal with removing all the little bits of sand or steel strands. Ed
I have been fiddling with the engine on and off for the past two weeks. I sanded down the paint on some covers.
I installed the bottom end in the frame with the new motor mounts. I have put on the shift linkage cover and output sprocket so i can now check for chain clearances when I am bracing the frame. I replaced all those crappy screws with allen bolts.
I went to install the clutch basket and found a large problem. the clutch basket must be assembled on the input shaft prior to the cases being put together. which now means I have to take apart everything I just did.
I was pretty bummed when i realized this, so I stacked the rest of the engine on there to see what it would look like. I think I'm gonna keep the head plain, or hit it with clear gun kote because Larry Cavanaugh did a beautiful job bead blasting it. APE blasted the jugs when they bored them out and its a bit darker so i think I'm going to paint that and sand the fins down. Always liked that look.
Also how crucial is this foam thing? I assume its for vibration reduction. I'm thinking about ditching it in an effort to reduce the weight of this bike, should I keep this?
Well I just held it up to the opening and it is much wider, i dont see how it could possibly fit in there without opening the cases. excuse my ignorance if there is something i'm missing. (i hope there is)
finally made some progress on the bike after 2 months of not doing anything. I cut out the templates for the gussets. I plan on cutting and dimpling holes in a few of them. Just got these for way too cheap,
I'm wondering how they good they are going to hold up for dimpling 1/8" steel. ive heard that the el cheapo ones and cause the sheet to warp when using 1/8" or thicker. I guess we'll see.
I think i need to make the gusset in blue bigger,
but im worried it will make it hard to access the coils or something else. does anyone have dimensions on what they have done? I really want to put a gusset in the front(in green)I havent seen it done yet, but im sure someone has. its probably overkill, but it will look so damn cool.
I'm worried about being able to paint the back of the green gusset once its welded in. Should i drill a hole in this? or can i just cut it out as i will add bracing to the outside that will be doing the same thing. thoughts?
I have also been waiting for my friend in Portland to finish setting up his machine shop. He recently bought a ton of new tools and had to move to a bigger shop. he tells me he has a lathe, mill, and a bunch of sheet metal tools. Hopefully I will head down there with the bike for a few days to to help my buddy crank out a bunch of the more technical things i want to do to this bike.
i've slowly been ordering the electric components for this bike. I wanted to ditch the mechanically driven gauges for something a bit more modern. I will be getting a GPS speedo and a electronic tach from speed hut. I talked to them on the phone and got them to send me the templates for the gauges so i could design them myself with out having to pay their art dept. $80 and hour to do something I am more than capable of doing. here are three designs, wanted to try and stay relatively close to the stock gauges.
this is with the "ticks" that same in the template
this is with the ticks redrawn, to look like the orignal gauges.
kinda like the redline like this. it will be easier to see out of peripheral vision. thoughts?
Motorcycle headlights have always seemed to create the character of any bike to me. I think of it like the way Vietnamese fisherman paint eyes on their ship, so it can see where its going. I wanted to upgrade to a HID light, and go to a smaller diameter lens. I searched long and heard to find a clear lens 5.75" reflector to fit my bi-xenon setup.
I found a 74 harley sporter XLH headlight that I really liked the rings on, however the HID bulb stuck out much farther than the back of the bucket, and i wanted it to be side mounted. So i had to modify...
first i cut the bucket down to the mounting ring.
then i taped up the bottom rings, centered it on my potters wheel, and packed a bunch of clay into the inside
then the profile was refined
then i sculpted some raised parts on either side to have it mount to.
This part was crucial, i cut some registration points into the plug, down to the top of the metal ring.
prepped to pour the mold.
I used hydrocal, mostly as an experiment to see how it would work with fiberglass, I also have a TON of this stuff on hand and its extremely cheap, I maybe used $0.15 worth for this small mold. Its similar to plaster, but much stronger and not as porus.
then I de-molded, and sanded with some 600grit to refine the surface further. here is the steel ring sitting in the mold. Those crucial registration points hold the ring in place.
I used mold soap on this, however in retrospect it didnt do crap, It is just what i normally do on a hyrdocal mold to seal it.
OK skip ahead a bit, I sprayed two coats of PVA into the mold, laid in 3 layers of 1.5oz fiberglass mat, using vinyl ester resin. I focused on getting a good overlap on the ring, which i also had sandblasted to give it some tooth. I then vacuum bagged it, which maybe wasn't necessary, but i wanted to make sure it got a real good bond to the ring.
OK so lesson learned: Hydrocal will absorb PVA even when sealed with mold soap. Normally the PVA will stick to the piece, in this case it stuck to the mold which made it very difficult to remove. I think if i did a better job of sealing the hydrocal it would have been easier to de-mold. I had to break the mold to remove the bucket. Here are some rough shots.
And here is it with the crap trimmed off and the light in. I think it came out pretty good. Its gonna need a little bondo-lovin to get it perfect, but it is a nice symmetrical base to start with. And its better looking than the original stubby harley one, IMO.
I agree, very nice work on your one off headlight bucket. That Hydrocal stuff you talked about; where can I get some? I wonder if the PVA would have worked better if you used a handful of coats of mould wax under it to seal the hydrocal?
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end