Was able to get around to looking through my pictures for more interesting shots.
My son and I ran into a stuck slide in one of the carbs, so it took us a long time to get it out, but when we did there was this look of shock on our faces and excitement. He spent about 2 weeks with me last summer and then I did a bunch of work on my own (powdercoat, engine clean, rebuilding carbs) until Christmas time when he came out again and we put the motor back into the bike and rebuilt the swingarm. 

I've been working on putting everything back together since then. Ordered the motogadget blue from ebay, and the Revival Signature mo.unit Deluxe wiring kit ( this one ), dyna-s electronic ignition, and some new handlebar button controls. I finally got everything wired up and working last week. Started putting covers back on.Getting closer to getting her out on the road.

Things to finish up:
Front Brake line (getting an adapter for the new brake lines and new rigid brake line in the front has been a bear)
Need to make sure the gas tank with rebuilt petcock doesn't leak
Recovering my seat (doing it myself)
New tires (being mounted today)
A few other odds and ends

I think I'm pretty much settled on the black frame, I want to return the bike to looking as much like a 73 Jaffa as possible, so after de chroming is done, alloy items will be hand polished, some steel will be chromed (mudguards, headers etc) and other steel items (swingarm, front hub etc) back to black again.

I have dropped the barrel of at the engine place, the MTC sleeves have metal O rings in them that need replacing and it will require a light hone to clean it up.  As with most things mechanical these days there is a waiting list, in this case 6 weeks, but I still have plenty to do in the meantime.
I have stripped the head completely down ready for a hydrablast clean up but will have to wait for the barrel to come back so I can get that done at the same time. 
The pistons are cleaned up and all shiny, when I was measuring the pistons and bore, these pistons are actually 72.5 mm, giving a displacement of 1090 cc.
 

Back to the Z1000A1, with the XJR1300 swing arm narrowed, it was time for a test fit in the frame. Not unexpectedly, the pillion foot peg mounts got in the way of the now wider swing arm.. they had to go. Everything went together ok, the frame still needs to be braced, and a few other lugs and brackets removed or modified.[img] i.imgur.com/zDgGj2T.jpg[/img ][img] i.imgur.com/ZLTNsVX.jpg[/img ][img] i.imgur.com/JMDKz2R.jpg[/img ]

NOBODY sees the elephant in the room.
Chain and sprocket offset from the center line of the bike is smaller on the KZ400/440s compaired to the 4 cylinder bikes.
I have  put KZ650 forks and tripples  along with a KZ550 swingarm on a KZ400.
This gave me Twin disc up front  and 36 mm forks. On the front a KZ650 hub with a KZ400 rim. For the rear I used a KZ550 swingarm[narrowed] with a KZ400 hub in a KZ650 rim.
This is with spoke wheels. Since you want mags you will need to do what I did on one of my current projects.
I machined the hub from KZ750LTD down to fit a KZ440LTD and used a different width space to square itall up.

We're coming up to date now, as all the work above happened in the last few months. Not an easy conversion, but the R6 front wheel is now fitted to the ZRX12 forks, had to space out the calipers by 2mm to align them with the discs. Resisting the temptation to fit the the front end to the bike, as I want to lower the bare frame over the engine which will be on its side, when the engine is ready. Thought the rear wheel will be a little easier, but it wasnt.. 

Fitting a rear caliper to the R6 wheel has proved more difficult than expected.

First attempt was with a small Brembo twin pot caliper, but the disc is so small.. 220mm .. that the caliper hit the hub before the pads were completely over the disc.. not good.

Second attempt used a standard R6 caliper.. which fits of course, but its mount is integrated with the caliper body, and is in turn made to fit the R6 swing arm... which is no good, as I'm using a ZRX1200 swing arm.. sigh

Third attempt used an old front caliper from some 90's Kawasaki.. it would fit, but a mounting bracket would look ugly, while the caliper itself was heavy and old..

Forth attempt. I needed to find a modern sliding piston rear caliper, as this type has a narrower profile and so would fit over the disc without hitting the hub. Eventually bought one made to fit a BMW 1250GS, which will work, so made a mounting bracket in 10mm alloy plate, which will be coated black.. hard anodised I expect. The torque arm and wheel spacers were made from stainless steel.

Fitting the R6 wheels to the ZRX12 forks / swing arm isn't straight forward, as the R6 front spindle is thinner and quite different from that of the ZRX. While the rear R6 spindle is 28mm Vs 20mm for the ZRX.

For the front end, I bought an R6 spindle from Ebay, which turned out to be bent.. so slight delay while I bought another. The plan is to use the R6 spindle with spacers to fit the ZRX forks..  Not sure yet if the standard 6 pot calipers will fit the discs ok with the new wheel in place, without the need for spacers..

While the rear should be easier to fit, as it'll just need a pair of suitable top hat spacers.

Finally decided what wheels to use. Had been considering Dymags, but at £2500 they were a bit over budget.. I wanted a pair of 17 inch, 5 spoke, lightweight, good looking wheels, with a 5.5 inch rear, in gold. After much looking, found a pair of new old stock wheels that fit the bill, from a late model Yamaha R6. Of course they wont fit the ZRX12 forks and swingarm, but I hope we can make them fit...  Discs are made by Armstrong.

I hear ya mate, i could have done things by not having the swing arm offset but It didn’t feel right to have the shock spacing uneven, I’ll take what photos I can in the next day or 2, Working on bikes have taken a back seat to my actual job now that summer is here but I’ll have a bit of time on the weekend in the garage.

wrote:

Well mate! i have a Gs1100e swing arm on a Z1000 A1 but there is a GSxr rear wheel on there and i spaced  the swingarm over to the exhaust side (right) by a few mm and the spaced the wheel back to the chain side to achieve the wheel center giving me equal distancing on the shocks which is around 8mm either side (8mm spacers on the inside of the shocks), if i can help with photos just let me know.

Thanks mate.   I have the spacers on the pivot bolt equal on both sides at the moment, I may just put them all on the left and see how that goes. I haven't made all the spacers up to centre the rear wheel yet, so that's not a problem either. My OCD wants everything to be perfectly squared up but it looks like compromise will prevail...! I won't be able to get back to the bike till next Tuesday, that should give me plenty of time to obsess....