KZ650 Sleeper Build (KZ1000 engine transplant)

Got my regulator harnesses wired up and ready to install.


 

Got started on making the exhaust flanges today but did not get very far when I discovered I needed to buy the next bigger size of hole saw.



I have all the hole positions center drilled and the cut off angles marked so I can easily pick up on the machining when I get the right hole saw in my hands.

I also made up some limit buttons to be welded on the head pipes behind the flanges so they won't slip off and down when installing/removing. Will fill up the centers with weld.



I found I have to fabricate a shim band to set the correct depth mimicking the stock split collars, the yellow band in the pic below :



Its just a strip of .10" thick sheet steel that will be welded on to make the flanges sit at the correct height from the exhaust port.
 

I cut my flange holes on my mini-lathe (which I know you have) using a "four jaw" none self centring chuck (was a bit of an ass to centre up initially)

 

Wookie58 wrote:

I cut my flange holes on my mini-lathe (which I know you have) using a "four jaw" none self centring chuck (was a bit of an ass to centre up initially)

  

Same here but left the spigots one piece to bolt to the head direct and included an internal step for the headers slip inside and sit against so they can be either welded on or held in with springs.

 
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Using a 4 jaw on the lathe would have been easier but unfortunately I don't own one. The hole saw is about $10 but your pictures tell me I should look for a used 4 jaw chuck to fit on my lathe.

I am trying to reuse these head pipe ends off some cheap header that was thrown in with the used engine purchase.



That pipe used the stock exhaust split collars and pipe holders (both items I don't have)

The pipes once assembled and welded will resemble a MAC system.

The head is set up for M6 studs which is fine for a street bike as I don't plan to take it apart that often.



 

Sprung for premium hole saw which was $12 on sale. Dragged out my belt driven drill press as my tiny mill was not strong enough without bogging.



The bit cut pretty good, was aiming for 1.53" and it cut 1.54" so that will be fine without any other work. Should not be an issue finishing the rest of the holes today.

Finished drilling these flanges a little while ago.





Now just have to cut them to size, mill flat edges, then shape the radii on the belt sander.
 

I got the flanges cut off by hand with a hack saw (Popeye arm) then I stacked them up so I can mill the cut edges flat.



Once the milling is done I will move on to grinding the radii.

I wrapped 1/4" bolts with copper shim stock to keep the ganged pieces from moving around.

I also laid out for some aluminum muffler mount brackets and a rear brake tab to convert a B frame to a C frame (for another project)

Even though it was freezing in the garage today I was able to belt sand the radii on the exhaust flanges and muffler mount brackets.





Progress is slow because of the unheated shop circumstances.

 

Made these depth shims to be welded onto the down pipes to set the flanges at the correct height.





These serve the same purpose as the stock split shims. Still need to clean up the down pipes as they have a combination of old paint and rust on them.

 

Checked the fit of the head pipe onto the head today, looks OK to me (shown without gasket)



Those studs/nuts are just to get it welded, ordered some SS studs and lock nuts for the final assembly.
 

Did some assembly welding on the exhaust last night.







I don't have a welder so I took it to a friends house, he is out in the country and works mostly on ATV's so he does not own a hydraulic motorcycle lift.

At first we thought we could get it up on his welding table but that 8 foot table is attached to a wall workbench style so you can only access one side at a time. Decided doing it on the floor would be best as he has a heated cement floor. Once we blocked it up on the bottom it was discovered we could only work on one side at a time anyways.

The head pipes are cut off a 1000 header, so two pipes are short and two longer by about 1 inch. We quickly found out the pipes were hanging down about 1" too far on the shorter pipe and more on the longer pipe. We ended up sectioning the longer pipe and have it on the inside cylinder. We are going to pie cut the inside top of the outer pipe and pull the open end into the collector to correct the down angle (angle seen from the side)

That is as far as we got last night and I am returning tonight to hopefully finish it.