TOPIC:

it's always exciting getting custom parts finished.
sucks having to wait to get to try them.
because,
theres always that lil nagging in the back of your head "going man i hope they fit"
they look nice tho.
keep us posted,

leon

Not at all Leon, Leaving the shop I had the feeling that they will be spot on
Or it was the keepers last words:
-We have your design in the cutter now if you need any more of them!
That made me feel calm

CNC is sooooo cool! Someday I want to convert my standard mill, or buy a used CNC to add to my shop. The endless possibilities of being able to machine complex curves in parts!

I think you will like the Nissins... they are my go - to now when an old bike needs brake upgrades.

I thought it would be an easy fix to drill out the caliper mounts on the fork legs and Helicoil them in order to fasten my new brackets to the fork legs.



So I bought a V-coil kit with M10x1,25 inserts,



Drilled out the holes with the 10,3 mm drill that came with the kit. But it was a bitch to get the inserts in correctly.



This was the first time I really scrutinize the holes and found out that they were casted and the two half’s doesn’t really align and has only been halfheartedly drilled at the factory. That doesn’t matter on the Zephyr as the bolts goes straight through and threads in the steel caliper bracket on the inside of the fork leg.
I couldn’t just re-drill them as I had already threaded them so with the help of a Dremmel I manage to get the molding flash removed.
With only a little filing on one of the fork legs that brackets fitted like a charm and the caliper looks like they end up where they should go.



Now we just have to fabricate two 8mm spacer to each side to center the caliper.
/A

Finally I gave in. Some of my old biking buddies from the eighties have asked me why I don’t rent a space in the vintage Japanese motorcycle man cave that they have established.
It’s hasn’t been hard to turn their kind offers down, firstly the garage is infested with Suzuki’s and an odd Harris Honda CB900, the last time I did the math I could count to at least five Katana frames. I have never really liked the Katanas. Secondly its 53 Km (33 miles) from where I live.
But after trying to rent a garage closer to where I live for the last two years I just gave in this New Year. I packed up my Gpz750R1 at Erik’s place, got my lift and tools that I had scattered and moved in to the Suzuki dungeon.
Believe me the green lit up the place and have finally a garage where I don’t disturb anybody as it is in an old factory building.
Anyhow, since this New Year I have probably got more stuff done than I have since the start of this project, but there is off course a major disadvantage. With 53 Km to the garage you just don’t fling over on a weekday night, so I am stuck with the weekends and to make it even worse it means no beer while tinkering as I have to drive back home after. I don’t know what is worst.
Then again things happens when you are constantly sober and in the garage at 7:30 Sunday mornings.

Bang! Rear set mocked up

Bang! teardown

Bang! frame blasted

Bang! frame painted


The frame is currently in the trunk of my car waiting for the weekly Sunday trip and the buildup will finally begin.
. . . . and I will be longing for amber . .

//A

Finally rebuild has started, but it doesn’t take long until one figures out that.
- oh right that should have been painted as well
Or
- Darn! that bracket has not been electroplated
I am quite convinced that is the change of garage diet from ale to coffee that is playing games with me.
Anyhow, it humming along nicely!



/A

Looking great!!

The really fun part begins. Anticipation for that first ride builds.

Ajsfire, Luckily I have two bikes in running conditions so I can give it the time needed. Right now it's the absence of spring that is the biggest hurdle to overcome and then I am not talking about the once on the Öhilins.

The Katana/GSX-R crews in the garage on the other hand has some late nights ahead of them. Most if them owns 5-10 bikes each and right now I have only seen one of them running on this side of new year.


/A

Work continues, the triple tees painted and new steering roller bearings in place the fork goes back on and the wheels goes the same way.

Started to get the wiring loom back on but I can’t figure out where negative cable from the battery is supposed to be fastened.
Could somebody give me a clue? Using the same bolt as the brake fluid reservoir on the right hand side?

/Anders

Forget it,
I my stupid mut lost it. It should run to the rh side engine case.
My bad.

Looking at my project it’s hard to believe that I have been working with logistics my entire life.

I started off with the excellent idea of first doing a dry build before starting work with detailing and the stuff that require finish. But right now it feels like I have kept my head where the sun doesn’t shine.

Lots of stuff finished, but I haven’t got around to work on the engine yet, but on the other hand the winter is soon here and the garage season has begun again.

So I am back at it again, head and cylinder off in order to get refurbished and a fresh coat of paint.

//A