CSR1000 Project Build

that is looking so sexy

Thanks Kwaker2000. Its still very temporary until I figure it out properly.Once Im happy with it,then I have to weld it up properly for the tail light mount and numberplate bracket (and also the rearset mounts)and fiberglass the tailpiece together (you may notice that I had to slice it down the middle to get it to fit over the wider frame rails) and also figure out a seat. still a long way to go.

Posty came yesterday with some more (ZX9R) bits.
Front mudguard.Though I dont know if Ill use it.Its a bit big and ZXRy.I may cut it down.

Some new switch gear.Being an American import, the CSR has no on/off for the headlight,which is a pain.Hopefully,come electric time,Ill be able to wire this in and get it working.

New brake/clutch controls with handels. I drained them and dumped them in soapy water to rinse out the fluid before a strip down.

I was wondering if Ill be able to make this work??

And yet another set of rearsets. Thats 3 pairs to choose from now.


OK.Thats it for now.Tomorrow Im going to tackle the seat/tail unit. Ive moved the frame to another workshop(with ventilation) and Ive got all my fibreglass stuff ready.First time.Fingers crossed.

Seat/Tail unit build.
(Part the 1st.)

Moved the frame to the ventilated workshop.First time on the road in years!!


I started by fiberglassing the tail piece together from the back ( I had to split it to get it to drop down over the frame rails)


Then,while that was setting I prepared the frame.


Then tailpiece on and lay out the fiberglass.




A very messy job but I think I did ok. (First timer) when I left it it was already hardening up and I saw 3 small air pockets.The rest of it seemed solid enough. Ill go tomorrow and pop it off the frame.
Next thing is to give it a good sanding and go over it with some filler.
I think Im happy with it so far.

im liking the tail piece very neat

Looking good! this may seem obvious, but wear a respirator when sanding or cutting the fiberglass. I see too many videos of people doing this without protection. When I cut or sand composites I wear gloves, respirator, and coveralls. The dust it produces is so terribly itchy, and hard to get out of your clothes.

I bought a mask last week and it worked fine,the smell wasnt nearly as bad as I expected. For the sanding,I just used a regular dust mask. Gloves of course. No overalls,so my clothes were covered in fibres.Threw everything in the washmachine as soon as I got home and it all seems ok.

Part the 2th
Well,I went down to the workshop this morning and everything was nicely hardened up.Popped off the frame no problem (I used vasaline as a barrier)




A bit of a trim with the jigsaw and some rough sanding brought me to this



Not too bad for a first attempt. It will need some farting about with . The back rim is not quite right



and some filling required



I had to join a bit on here as the line was a bit high. The front part,the 'tank hump' Im still not sure about. Ithink ill have to cut it out and remodel it.


But thats it for now. Im happy with how its going and Im pretty confident that itll all work out and Ill end up with a nice tail/seat unit. Itll all have to wait for now though as I ran out of goo and Im busy this week with work.Ill be back to it next weekend.Fine tune it and get it sanded and filled.

cool coming along nicely mate

really cool tailpiece :evil: !

with so many people modding 81 and later kz's there may be a lil market for a few of those in the classifieds. :whistle:

keep us posted this thing is starting to come together.

leon

yes i would like to see some advertised if possible

No eBay APP ID and/or Cert ID defined in Kunena configuration

This is the ducks arse I bought but like I said,it wouldnt fit on the CSR. Also,the original CSR seat is pig ugly and as big as a mattress. Thats why Ive gone for a one piece unit and the only way to get one was to make it myself.
Ive still no idea what Im doing.

OK,While the site has been down,Ive actually made a bit of progress. First up,the seat pan.I did a bit more work on it and got it filled out a bit.Its more solid now and more symmetrical I realised that I hadnt accounted for the airbox which sits above the frame rails. So, I had to chop a bit out to allow for that.

I talked to the seat makers and they reckon that I need to make a second pan to velcro onto what I have,then they fit the foam and cover to that. So thatll be the next thing.

I got the spacer/bushes for the rearsets and figured out a good placement for them


Then I had a day off work and stared at it all for a while. Ive been getting frustrated with having to farm out a lot of the work,not just because of the money but because of the fact that,all these skills are things I want to learn to do myself.So I thought 'Fuck it ,Ill have a go at welding it up myself' i found the welding machine ,a mask and some rods and got stuck in.
My first weld

Not too bad eh? The rest didnt go as well



Anyway,It turned out that I was using stainless steel rods,which is why it went so easy. So to cut a long story short,I had another go,using a mig welder.That also didnt go so great so,I took it to my local Bike shop and they did it properly for me.
Nothing ventured,nothing gained