Doctorot's '78 KZ1000 build

I trimmed the panels and glued some florists foam on with gorilla glue. then shaved it down .

Went heavy with some cheap body filler. I packed it in the seams of the frame after coating it with grease again. this let me use the frame as a guide for forming the side covers.



Using a angle grinder with a flap wheel, an orbital sander, and a hand block i first trimmed the edges flush with the frame, the sanded down the face, then beveled the edge. Each time carefully comparing the covers to each other, and marking where filler would need to be added. I switched around brands because I had a couple different kinds left over.


Then repreated this process about 10 times until i had all the planes pretty damn close to perfect, i used a light to check them for straightness.


I then thought they were a bit plain and decided to incorporate a design element from the tail and fender i am using. I sanded in a concave-curve that then rounds off slightly at the edge. Using different soft blocks I slowly added it, making long even strokes with 120 grit paper.



I did this around 3 of 4 sides. I was happy with the state of the covers at this point and sprayed them with a quality "high build" primer.


now i'm ironing out the fine details with a combination of these tools. lots of wet sanding with 320 at this point..


Its starting to come together. hopefully i will be ready for molds by the end of the week. Also i am extremely thankful that i have a nearly empty shitty garage to make a massive dust cloud in. Respirators are your friends.

the two wheel trips through asia has to be amazing :ohmy: .

have you done any good write ups about it?

the side covers are coming out awesome ! :evil:

can't wait to see how you attach them.

leon

Ok doc. Thought you fell off the face of the earth. I'm back in class proceed.

Leon, i haven't done any write ups on the road trips i did in Vietnam or in Laos. i did take a ton of photos though. Driving there is insane. Its all death and trucks and maniacal old women on bicycles. I have been chipping away at the body work plugs. its time intensive for sure.

I know from the tail pieces you made me that the end result will be nice.




Keep us posted, I can't wait to see the results.

Leon

excellent

Sweet! im glad you are using that tail piece!

heres a couple more pics of road tripin solo through Nam

I wish i had some photos of me riding that little honda with my massive backpack on the back. Im 6'6" and that thing was like a clown bike

I'm with the other guys, a picture log of an adventure of that magnitude would be epic. You have to share!

On to the bike. The custom bodywork is Awesome :woohoo: Time intensive on stuff like that is an understatement!

+1 on trip pics and stories (like, Where did you find a "DeathRace" helmet? :woohoo: ).

Glad to see you are back--yours is a great thread. DoctoRot and Porchev back=good times! Looking forward to seeing those bodywork pieces.

Doc, I'm looking for some rear sets and in reviewing your previous posts it looks like my frame is about like yours. You said the guy you bought them from said they wouldn't work, why was that? Are they not for a KZ? Just wondering what you ordered, because it looks pretty much like a shoe in...............................Oh yeah, sweet build.

nivlac wrote: Doc, I'm looking for some rear sets and in reviewing your previous posts it looks like my frame is about like yours. You said the guy you bought them from said they wouldn't work, why was that? Are they not for a KZ? Just wondering what you ordered, because it looks pretty much like a shoe in...............................Oh yeah, sweet build.

They are tarozi rear sets. i bought them from fast from the past. they are for the KZ1000 A2, they dont offer them for the kz1000LTD. the difference is the A2 uses a slightly different pushrod for the MC, i ended up getting that with the rear caliper from the A2 i swapped wheels with, so the problem solved itself. all you need is the rear MC pushrod from and A2 if you have and LTD and your good to go.