And finally, Wookie's 82 begins !

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25 May 2024 12:38 - 25 May 2024 12:38 #899716 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !

Is this manifoil fitted on the back side of cylinders where the oilmanifoil is fitted or on the cooler?
On the top of the motor behind the cylinders (it replaces the stock oil switch housing)
Last edit: 25 May 2024 12:38 by Wookie58.
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25 May 2024 12:43 - 25 May 2024 12:44 #899717 by Rolf1976_KZ900
Replied by Rolf1976_KZ900 on topic And finally, Wookie's 82 begins !
Okay thanks so then you will run 2 braided an fitting hoses on the side of cylinders
Last edit: 25 May 2024 12:44 by Rolf1976_KZ900.

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25 May 2024 13:00 #899719 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !

Okay thanks so then you will run 2 braided an fitting hoses on the side of cylinders
Over the top and between the carbs is the plan (1-2 & 3-4)
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26 May 2024 13:28 - 26 May 2024 13:30 #899765 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !
After spending most of yesterday with a butane torch and wire wheel stripping powder coat from the top half of the frame ready for the "next phase" I decided to notch the cross race so I can geta better angle on the oil hoses without putting any stress on the hose where it enters the fitting which could cause it the "kink". Then onwards, I have mentioned a few times that I think the factory frame braces are "only a mother could love" ugly and I know if I don't address it it will bug me when it's finished. So out with the cutting wheel, no turning back now 
This turned out to be PITA with multiple different angles to take into account when notching the pipe (hence why I have only done one side so far !) still on the upside, looking at the rest of the frame with the paint removed my crappy welding could pass at factory   It's holiday in the UK tomorrow so hopefully will get the other side wrapped up. I think it looks way better and should also be significantly stronger

 



Last edit: 26 May 2024 13:30 by Wookie58.
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26 May 2024 16:47 #899774 by Scirocco
Replied by Scirocco on topic And finally, Wookie's 82 begins !

Is this manifoil fitted on the back side of cylinders where the oilmanifoil is fitted or on the cooler?
Yes,right there.Here are some pics about the location and my oil cooler line routing.

 
 
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27 May 2024 00:42 #899794 by willemZ900
Replied by willemZ900 on topic And finally, Wookie's 82 begins !
I have the same line routing on my Z, works great, almost no lines vissible
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28 May 2024 02:21 #899841 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !
I can't believe this is the second anniversary of me starting this build (mainly weekends) but having waited so long I refuse to compromise on how I want it to be. I am a "glutton for punishment" and have chosen an extensive "re-work" to get what I want but there is light at the end of the tunnel   got the other brace in yesterday and the coils mounted so still moving forward 
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28 May 2024 05:42 - 28 May 2024 05:43 #899847 by calum
Replied by calum on topic And finally, Wookie's 82 begins !

...but having waited so long I refuse to compromise on how I want it to be. I am a "glutton for punishment" and ...

 
This sounds strangely familiar...
Last edit: 28 May 2024 05:43 by calum.
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01 Jun 2024 13:26 - 01 Jun 2024 13:28 #900092 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !
I've been getting on with working back through the frame and adding mounts for electrical etc today. I don't have space in the headlight for any connectors due to the mods I have done on the bowl to make everything fit. I decided to create a "coupling station" in this vacant part of the frame which will house all the connections for the coils, tank sender and front end. As with everything else on this build I have tried to build in longevity (I don't want this to be one of those custom builds where you spend every weekend fixing something hopefully!!)I am useing weatherproof "Deutsch DTM" connectors (copies, originals are £12 - £14 per plug and socket set but these seem to be pretty good) in the hope I can avoid "corroded terminals" which curse these old bikes. The mount is fiddly as the cut outs have to be "dovetailed" but they are nice and secure when pushed into place. I still have another row to do but Mrs Wookie has plans for tomorrow !!! 
PS: coils need shorter bolts 









Last edit: 01 Jun 2024 13:28 by Wookie58.
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08 Jun 2024 12:20 #900464 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !
Well today has been one of those "WHY DID YOU DO THAT YOU DICKHEAD" kind of days   I had this idea to put a channel in the front brace to run the wiring through to the connector station. However when I cut into it two things became apparent, firstly it was thicker than the side braces I removed therefore significantly structural and secondly because of the way the tubes run behind it there wasn't room for what I wanted to do anyway   I have now removed a little more and replaced flat plate with 3mm walled tube which is also tied into the central box section (which is wasn't before) so I guess the upside is that it is now way more rigid than it was before   now I can get back to moving forward 

 
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15 Jun 2024 11:27 #900762 by Wookie58
Replied by Wookie58 on topic And finally, Wookie's 82 begins !
Managed to get a bit more done today, I have finished the mounting for the connectors at the front end and also made a plastic cover for underneath to protect the wiring and keep the weather out. Also managed to box in the notch I had to make in the brace to clear the airbox 

 









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15 Jun 2024 19:58 #900778 by TexasKZ
Replied by TexasKZ on topic And finally, Wookie's 82 begins !
Excellent.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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