Z650 / GPz engined Restomod

Came to fit the Gold spot calipers, only to find they didn't fit with the discs in place. Odd as the front end is from a 2003 -4 R6..  After further checking, it seems I had bought discs from a 05 R6.. which are 10mm bigger in diameter.. So they will have to go, and the correct discs bought. Decided against buying a used pair, didn't want the risk of worn or warped discs. Ordered a new pair of aftermarket discs for a good price from a company called Comet.. probably Chinese, but they have some good reviews on various forums. 

Also weighed the bike as it sits now.. 81kg in total. No idea how that compares to a standard bike in the same state, but for sure its a lot than stock. 

The replacement discs arrived, made by Comet, probably Chinese, but they had some decent reviews, and at £79 each, same price as a used and possibly worn out OEM R6 disc. One change, I swapped the Gold spots for Blue spots, as the gold spots colour didn't look right with the gold of the wheel/disc. Luckily the Candy apple blue paint is a good match for the new calipers.

With the brakes fitted, I could measure the length of brake lines I'll need, and ordered them from HEL. 

Fitted the dyna coils, note the heat shrink used as insulation on two of the spacers.

A few small changes too, such as machining down the rear brake torque arm, as it looked too fat..

Custom HEL brake lines now fitted, front and back.

looking good

Since I used IMGUR for my photos, they've all disappeared due to the legal changes in the UK. They still appear if your not in the UK.

What free site is everyone using instead for image hosting?

Anyway, I'm now able to work on the bike again, with the bottom end of the engine done. Just awaiting a few parts to fit the top end.

One of the boxes of engine parts that should be in my garage has vanished. Searched everywhere for it, but no luck. That box contained all the engine covers, camchain idler gears, blades etc. Have to find replacements on ebay/Z Power. Very annoying. No doubt in six months time, the missing box will turn up..

Moving on to the carbs, I did find one carb had a oddly damaged float, along with a missing spring and rubbish black paint.. took hours to remove it all and rebuild the carbs. The rusty choke rod is no longer available new, so going to try to make one in stainless.
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Looking good. I re-plated my choke rod which turned out ok

Replating would be ideal, I don't know any reliable plating companies near me. I may buy a DIY kit at some point and see how that goes.

 

 I use Flickr for image hosting. 

Got the engine covers back from being powder coated. The original  alternator cover was damaged, so I bought an older style one instead. Loosely fitted them just to see how they looked on the engine..

 

About to fit the block, when I noticed a problem, one of the liners had moved. Possibly with the heat used when the block was coated, or when a broken fin was repaired.

Took it to my mate and we used his hydraulic press to get it flush with the block deck again. Its now much better, but not perfect. There's a tiny raised area you can just feel with your finger tip. Not sure if its worth having the head ground, that could cause other issues.

Have to remind myself its almost 50 years old, so I'm going to try the' 'wet n dry on a plate of glass'' method to see if that improves things.. 
 

That's too much. Heat the block and use your press again. Wait until everything is cooled before releasing the pressure. Yes I know you have fresh powder coat, you'll have to be careful heating.

Lee have you powder coated the block ? I believe the powder melts at around 250 degrees so maybe an issue?