'78 KZ1000 makeover

Occasionally I get to machine some lexan parts at work. Makes for really cool looking work. Mark, I have some professional questions to ask you. PM comming your way.

Adam, I love the curved braces. I just may have to put a roller on the short list of next tools to buy. Definantly getting some good ideas for 2.0! I tried to bend some potential braces by using my hitch on the truck. Yeah I bent em allright. Couldn't get any two the same, they were like snowflakes.

X2 Mark...can you make me a Lexan fuel tank??? :ohmy:

Thanks Josh. It was a matter of convenience, using the rolled tubing that was otherwise useless. It just turned out looking cool. Now, if I can just get Mark to make me a Lexan fuel tank, I'll be in business!

I guess that you wouldn't have any excuse to run out of gas. Lets see, lexan fuel tank, carbon fibre side covers, what are you gonna make the tail piece from? Kevlar?

I do have some carbon/kevlar hybrid cloth. It is bitchin looking material, but a PAIN IN THE ASS to cut. I bought special sissors to cut the kevlar, and ended up sending the sissors back to the MFG 3 times, the last time with a swatch of the fabric because I couldn't cut the stuff. They ended up calling me and telling me they couldn't make the sissors (advertised as kevlar sissors) cut my supplied material. So its sits in my rafters, rolled up and waiting until I spend the money on some high dollar kevlar cutters. But seriously, the 2x2 twill pattern with alternating black and yellow would look sweet :ohmy:

I tried to cut the bead from one of my old roadrace bike folding bead tires out of curiosity. Those folding bead tires have about a 3mm kevlar bead in them. Needless to say that stuff is hard on a pair of scissors, shears or whatever. It seems that everyone on the boat building forums recommend Wiss brand scissors to cut the Kevlar cloth. Apperantly, the stuff is a pain in the ass to wet out when you start with the epoxy. However, you will have the vacuum bagging stuff. That's probably the best solution.

Once I get a process in place and the bugs ironed out, I'll buy some decent kevlar shears and lay up a set of side covers with the hybrid fabric. I have also been looking at 1/4 turn aircraft hardware for the side cover mounts. I like the ease with which a stock cover comes off, until one comes off at 85 mph on the 405 somewhere around LAX. I don't like 3 machine screws holding the cover on, casue its a pain in the ass to take off if you need to to get the fuses or whatever. I was also looking at the instrument cups.....hmmm....

PLUMMEN wrote:

porchev914 wrote:

I have been way too busy with side projects! Between the week I spent playing with my new tubing roller, and the time I've spent putting together the stuff I need to make side cover molds and vacuum bagging supplies for carbon fiber covers, I have lost sight of the main objective! I got back to the roots this afternoon and finished off the front cradle cross brace. It's not perfect, but it's close enough that with the header in place, NO ONE will ever notice.

Now the only bracing I have left to do is the steering head and rear top tube sheet bracing, with the top center to perimeter tube braces, and I'll be done with the frame. The sheet braces will be MUCH easier that that damn front "X" brace or my upper shock mount :blink:

have you tried removing the mototor with that bracing yet?

Thanks for the heads up Plummen- engine removal was normal with no interference from the bracing

And with the engine removed, damn, the frame looks alot different! Now I just need to weld up the stuff that's tacked in place and finish off the subframe.

I was thinking of making my battery box out of composite, either fiberglass or carbon. Has anybody else done that or seen pics of it?

porchev914 wrote:

X2 Mark...can you make me a Lexan fuel tank??? :ohmy:

I knew u would ask me that so i made 1 last night. its in the mail.:laugh:

Damn Mark, one step ahead of the game. :laugh: :laugh:
Incidentally, my Yoshimura Series II exhaust is up for sale in the classifieds. I can't use it, and I need some chedder to cover the cost of irishwills custom triple clamps :woohoo:

great work,good progress.
i like the curved brace tubes(naturally ).it looks like something i would pull off.

kzrider1 "oh they are kinda a bit(h to weld the inside top edges even with straight tubes"

kzrider2 "yeah you are right"

kzrider1 "okay lets make them outta curved tube"
hehe .

nothing like taking a semi tough job,and adding in design elements that makes it a real bear to weld.
truly a man after my own heart :laugh: .
i wouldn't do it any other way,good job.

leon