TOPIC:

Michel3007 wrote:

That would be great, thanks Wookie

Mail sent 

Seasons Greetings everyone!

My "Tribute" build received a nice addition this week...

The original GPz 1100 B1 instrument cluster that was on the bike was "beyond restoration" and had to go.

I searched far and wide for a "genuine" Lawson Replica cluster, but ended up  replacing it with one from a 1982 GPZ 1100 B2, that I sourced on eBay.
However, this cluster was never used on actual Lawson replicas, and it bugged me...

Two months ago, a fellow KZR member, Ojisan Rider, posted a few pics of a disassembled / damaged cluster that he was planning to "throw out", but was asking if anyone wanted it. Duh!

After a few emails we agreed on a (super reasonable) price: so the bits were nicely packaged and were soon on their way to me, via USPS, from HAWAII !!! 

This is what it looked like:
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To say that the speedometer mechanism was "un-servicable" would be putting it mildly.

However, I had hoped that the speedo mechanism from my B2 cluster would be a " drop-in" replacement!

I spent some time cleaning up the bits, after which I performed the transplant "surgery"...

I am very happy to report that the "operation" was a success!

I installed new 12volt, 5 watt, peanut bulbs, and closed up the unit.
I was eager to see it installed on my bike...

Before / After......



I removed the oil pressure signal "inverter" that I had made to suit the B2 instruments, as well as some wiring bridges that were required to prevent the missing side-stand switch and battery electrolyte low level from permanently illuminating the warning LCD and bright red LED!

This is the final result:



​​​Thanks again Toshi, (Ojisan Rider), most appreciated! 

My "Tribute" is nearly indistinguishable from an actual Lawson replica! (I said "nearly" ! )
What remains now is a Kerker megaphone... and I'm hot on the heels of one!
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H.

Nice job.

One man’s trash…..

I can't believe my luck! 

I found a Kerker megaphone on my local FakeBook  Marketplace for $8 !!!
Seriously!



​​I'm not sure what model it is from:
It is chrome plated, and has an ”XR" stamped near the mounting bracket.
It is in fair shape, but the cast aluminium baffle end cap has been hammered / butchered... but I think I can "repair" it...
more on that later....

The Kerker badge was not included... what to do?....
I have seen those badges sell on Ebay for $150!!! 
I thought I wound try and make a replica 

First, I traced the letters of the badge (from a picture on an Ebay auction) 
Then I could design a press tool that I could 3D print..

Here is my tool design:

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I have some 0.2mm aluminium Litho printing plate, which is perfect for a badge.
Here is the printed tool with the blank litho plate...



I had a local decal company cut a "mask" from "peel and stick" vinyl so that I could spray paint the black areas of the badge, which, when the mask is removed, would leave the shiny aluminium letters exposed...

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Here is the unmasked, painted aluminium litho plate, placed in the press tool...



I placed my 3D printed tool between two 25mm thick steel plates and pressed it on a 10 ton hydraulic press.
(the gauge showed 8 ton)



I was totally shocked by the result!



The letters are perfectly "embossed", about 0.4mm (1/64 inch).



I hope this is not considered to be "counterfeiting" !!!

H.

Loving your work as always Howard 

Very impressive!

Very Nice and clever work!

Jonas_Z1000j wrote:

Very impressive!

I admire your use of the word 'impressive'!

WOW........You never fail to impress me with your work, I bet you have a hard time sleeping thinking about the project at hand.

Great Work!!

Impressed, embossed... 

.... I bet you have a hard time sleeping thinking about the project at hand.
 

Naah, with 100% Grade A, full extract CBD oil... I sleep like a baby!
(and I don't mean I wake up every hour to pee )
 

So, here is the end-cap for the Kerker megaphone, as received...





It had been hammered into the megaphone, and it took quite a bit of heat and force to remove it!

I machined a top-hat section of aluminium and tig welded it into the "crater" left by the philistine that tortured it.
(The casting was very porous, and I struggled to get a good welding "fill".

Then, on the lathe, I cleaned up the welding and polished it.





Looks ok now...



I am fortunate to have access to a small laser engraving machine at work.



 I made a circular "Kerker" text template:



The engraving process "erodes" the material with concentrated light / heat.



I repeated the process 4 times, to achieve a letter depth of 0.5mm.
I am happy with the result, and, to quote Allen Millyard: "I am well pleased with that!”



It will be painted with high heat mat black paint ...

H.