'76 KZ900 (ZRX1200R) Build

lookin good cory!

keep up the good work sir!

leon

So not much done on the bike this weeked. Fitted my Ducati clutch slave to the D&G plate by boring out the stock mechanical clutch hole, and drilling/tapping 3 holes for mounting with SS Allen fasteners. Routed the hose and installed the new titanium banjo bolt. Nice and tidy I think. Now I just have to extend my stock push rod. The remaining time was spent measuring for my remaining axle spacers for the spoke wheels. What a PITA trying to get all the measurements right so everything lines up and locks down appropriately.

Next time wil lbe cutting some stainless steel for spacers and aluminum for my brake rotor adapter for the rear rotor.

Cory

So it has been a LOOONNNNGGG time since I have worked on the bike. I did not get as much done as I had hoped, but made some crucial steps. First off used my fancy new trailer worked to get it to my brothers for some lathe work.

And Remington says "Hi"......So does Winchester...

Started by cutting my poker drink cups down, and turning the spin-on gauge retaining rings down to press into the cups, violia custome polished SS gauge cups.

Then moved onto front axle spacers. A PITA to measure, but got SS spacers cut and installed and everything lines up well.

Moved onto the back spacer. Used the stock RH side rear spacer and it puts the wheel centered perfectly. Cut a new SS LH side spacer, and again everything works beautifully.

Here is where everything goes sideways...... Next morning took a look at my rear wheel as it spun away and noticed the cush drive I machined was wobbling slightly. Just the center floating hub, not the basket that was bolted to the wheel. Started to play around and found that I need to address something I had feared since machining it. I needed an inner lip to seat the bearing against. I had to cout it out, and thought I might be able to get away with it, but alias no. So blew the cush drive assembly apart, and moved the double row cush bearing out to flush with the outside about .206" and made a new inner seat that pressed in with a deep bevel so that now it is pressed and trued, it will be welded in place, then the back side will be trued for clearance. So I got around the clearance area, and finally got my cush drive right. Will need to take .206" off my LH side rear spacer I just made, and make a new inner cush spacer that is .206" longer than my old one.

Next on my list is my Ducati clutch slave push rod extension, my rear brake rotor adapter, and trimming my clip on tubes shorter. Also starting to finish my gauge panel with some cutting and then engine turning for a final finish.

Cory

Slight update...... cush drive failed, so I am contracting out on my original design to have one part of it made I cannot. So more on that to follow....

On a side note, got the rear brake rotor adapter made. My countersink failed while setting the mounting hardware and caused some chatter, so I will have to get another and just make a cleaning pass, but other than that, it is done.

Also my bike is getting a slight face lift.....courtesy of Indian Motorcycles.....

That is it for now......will have more from this weekend to report.

Cory

can't wait to see how the indian headlight looks on there !

leon

531blackbanshee wrote: can't wait to see how the indian headlight looks on there !

leon

Thanks Leon!

I just loved the swoopy 33-34 Ford headlight look, and I think it goes with the lines of the bike and my new tail....will have a floating mount and billet "clip on" turn signal mounts.

Cory

Can't wait to show this so...... my design for a cush drive has become a reality but only because of a fantastic ZRXOA forum member, Mr. Stites had the generosity and willingness to take on the job! Thanks to Leon and Les for their willingness to try and tackle this as well.

Little eye candy on the way.....

Cory

That should be in an art museum - it's really a beautiful piece of sculpture! Ed

Thanks, one more shot....

Cory

Wow! That is too kool for skool.

I look forward to a ride report.

Beautiful..... x2 on that being art. Very cool! :woohoo:

Thanks guys! I am glad I found someone to make the one piece I could't. I hope the second Cush piece I make looks good enough to compliment it! Nice thing is this Cush drive should be light, and easy to mount up to any Harley hub in case anyone wants to build custom spoked wheels.

I am willing to help people figure out their own if they want to try an duplicate these wheels for other bikes.

Cory