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Doctorot's '78 KZ1000 build
- Beezy
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1978 Kawasaki KZ650
1981 Honda CB650
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- DoctoRot
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- Oh, the usual... I bowl, I drive around...
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- DoctoRot
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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.
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- DoctoRot
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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.
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- 531blackbanshee
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leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!
billybiltit.blogspot.com/
www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work
kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
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- DoctoRot
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- Bad Kaw
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- Flying Squirell
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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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- porchev914
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- Whats that? Half of my swingarm is missing?!?!?
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FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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- DoctoRot
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I buy mine locally from Seattle pottery supply, I usually order it by the ton or half ton, so its pretty cheap. Most ceramic supply places will have some, usually in 50 or 100lb bags.porchev914 wrote: That Hydrocal stuff you talked about; where can I get some?
If I was going to do it again I would use the wax. it had been so long since i made my tailpiece i forgot that step of the process. I think i would also try sealing it with some primer/sealer and sanding that down first too.
These came today, the faces I designed are looking sweet! i cant believe how lightweight they are compared to the stock ones. sorry for the crappy cell pic. camera was dead.
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- Hatchet
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- It's better in the wind.
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Wishing you all the best luck working on this bike, I'll be watching your progress with great interest...
Also, I like your taste in boots (and arachnids).
Bikers are a rare breed.
Harley riders are a dime a dozen.
'83 KZ750 LTD K1. "Don't make me get the belt..."
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- mark1122
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- Keep twisting it
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Way to go.
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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- 531blackbanshee
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leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!
billybiltit.blogspot.com/
www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work
kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
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