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CBRRRT
23-09-2008, 06:42 AM
http://www.streetfighters.com.au/forum/upload/11450379454345.JPG


My Blade

CBRRRT
23-09-2008, 06:49 AM
http://www.streetfighters.com.au/forum/upload/103703899627421.jpg


This is where it all went PETE TONG!

CBRRRT
23-09-2008, 06:54 AM
http://www.streetfighters.com.au/forum/upload/103703899627004.jpg


Now thats what hapens when you dont look after your toys

CBRRRT
23-09-2008, 06:57 AM
http://www.streetfighters.com.au/forum/upload/11450379435303.jpg



Time to have a little rethink

CBRRRT
23-09-2008, 07:00 AM
http://www.streetfighters.com.au/forum/upload/103703899627429.jpg


R1 Seat unit follows the curved line of the tank, and I like it!!

CBRRRT
23-09-2008, 07:03 AM
http://www.streetfighters.com.au/forum/upload/103703899631813.jpg


Enter e-bay and more R1 parts. Sub-frame, undertray etc...

CBRRRT
23-09-2008, 07:06 AM
http://www.streetfighters.com.au/forum/upload/11450379462949.jpg


selotaped on a zorst, and slapped on a splash of primer.

CBRRRT
23-09-2008, 07:10 AM
http://www.streetfighters.com.au/forum/upload/103703899625517.jpg


This is about where I am at the moment. I did a few bits and bobs last weekend but not yet taken any photos, though as soon as I do I'll stick them on here.

debaser
23-09-2008, 10:39 AM
looking mint man. You keeping one exhaust or going for the twins. i just found an outfit that sells baffles that open the original r1 pipes up. Sound nice. gettiing some for the r1 exhaust on my gixxer. 90 american is ok compared to 600+ for aftermarket.

RED ZX
23-09-2008, 10:44 AM
very nice.

now you just have to clean up the wiring at the front, pick a headlight, and maybe a set of bars, and then the good times of hooliganism await.

Funkenfresh
23-09-2008, 02:59 PM
more side profile pics please... looks great!

Brodie
23-09-2008, 03:20 PM
Looks awesome so far!

CBRRRT
23-09-2008, 05:04 PM
http://www.streetfighters.com.au/forum/upload/11450379464890.jpg


Thanks Mates,

Yes there is going to be a second pipe on the other side, but I couldnt resist sticking one on for the photos, lol ;) You know the score ha ha.

I found a guy on e-bay that said he could rebaffel the pipes for me, but I'm not sure if my carbs will need to be rejetted. Any thoughts on that one guys?

Your Gixer looks the dogs bollocks mate, I love what you have done with it, it looks harder than a pair of 18 hole Dr Martins on a 70's skinhead. I'm green with envy [:p]

I have to admit I am shite with wiring so I'm gonna have to get someone in to tidy things up a bit up front. I have two sets of bars I had on my 1200 Bandit. I could never decide what ones I liked best, so I choped and changed every other week ha ha, sad twat I know.

How ever did we do mods to our bikes before e-bay came along? seems like the skys the limit.

I have a VFR single sided arm to go in soon, and I saw else where on here someone had put a car wheele on it, that was impressive!

Anyway I just got to work and I guess you are all in bed now, so I'll check in again tomorrow and see if any of you nutters has any thoughts on re jetting my carbs to suit the R1 zorst.

HueyonaBlade
23-09-2008, 08:21 PM
http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=5060&SearchTerms=master,and,apprentice

Here you are matey read it and dream of what could be I have a few times;)

CBRRRT
23-09-2008, 08:59 PM
http://www.streetfighters.com.au/forum/upload/11450379455789.jpg


My 5.5J rear wheele that will take a 180 section back tyre, and just to the rear of that is my 96 750 VFR swing arm.

CBRRRT
23-09-2008, 09:03 PM
http://www.streetfighters.com.au/forum/upload/103704337224249.jpg


I made some infill panels and the lower sub-frame bracket is clearly visible, although when its painted satin black with the sub-frame it should blend in a bit better.

CBRRRT
24-09-2008, 12:21 AM
Hi HueyonaBlade,

Take a look at the link below and follow your dreams Matey, follow your dreams....... [^]

http://www.tireqwik.com/sssa/menu.html

Shadowzone
24-09-2008, 12:28 AM
CBRRRT - I've had plenty of cans opened up in my time and never had a jetting issue with it.

In saying that, you're changing the exhaust to what looks like a completely different one so it may

play up. I couldn't see it happening, but it is a mechanical animal so like women once you play with

them a little they can get a bit stroppy. Nah seriously mate all opening them cans up does it lets it breathe a bit

easier. If you're going from 4 --> 1 to a 2 --> 1 system it may be you need to get it rejetted. I've not done this so I wouldn't be 100% certain either way.

To avoid this I suggest running 4 --&gt; 1 --&gt; 2 and you shouldn't have any issues. <s>But like a woman you no doubt will</s> [:0]

CBRRRT
24-09-2008, 12:49 AM
http://www.streetfighters.com.au/forum/upload/103704408616659.jpg


There are two types of 750 swing arm the one above is the one YOU DON'T WANT This was an expencive mistake I made, so double check with the vendor that the shock linkage is the same as your blade. The correct arm comes off a 94 to 96 VFR 750. Before 1994 they are wrong wrong wrong :(......... and you dont want that now do you!

I'm not bitter :(

CBRRRT
24-09-2008, 12:54 AM
Thanks for that Mate,

I met a guy today that said it might be an idea to take the bike to a dynojet run and get new air filter and once the zorst is done have it stage two'd. To be honest, it made me go a bit chubby to think of a few more pony's

Shadowzone
24-09-2008, 12:58 AM
Hey man since you don't want it send it to me.

I'll take it off your hands and relieve you of your expensive error for free!

See I'm a good bloke after all. Actually that's an interesting point since I have a 96 Blade I was planning on doing the conversion to.

The Gixxer conversion won't matter so much cause it's going to need some work anyway, so I'm not real worried about that.

I think my housemate is concerned about me planning on doing the build in the loungeroom, but since the garage is full and he wants

his 1960something VW Golf to stay in it there's nowhere else. Oh well he'll get over it I'm sure.

What's the difference in the shock linkages? Can it be fixed with the use of a different shock?

Shadowzone
24-09-2008, 01:06 AM
yeah mate once you've got the pipe done go and get it jetted and airfiltered and throw an advancer on it as well. Why not. saves hassle.

Mandatory for most bikes now days I think.

CBRRRT
24-09-2008, 01:09 AM
http://www.streetfighters.com.au/forum/upload/11450379452062.jpg


Its right there under the bench mate, on top of the tool box. Its yours if you want to pop round to collect it.

The difference is that the shock link sits between the two tangs on the wrong one, but if you look at you Blade linkage you will see there are two plates that sit each side of the single centre tang on the right one. This causes problems when you try to link the shock to the arm on the wrong one. Now my brain hurts.

CBRRRT
24-09-2008, 01:12 AM
About to leave work to drive home, I'll check in a bit later matey.

Shadowzone
24-09-2008, 01:14 AM
Gotcha. I understand completely the attachment issues.

It may be a while before I'm round your way, given I'm lapping up the sunshine in Far North Queensland.

Do appreciate the offer though.

Next time I'm through I'll be sure to pop in for a cup of hot chocolate...

CBRRRT
24-09-2008, 03:33 AM
http://www.streetfighters.com.au/forum/upload/103704465626461.jpg


Anyone else interested in the conversion this may help you to make the right choice.

The one on the left is the right arm, and the one on the right is wrong. they also have some codes on them that refer to the year of manufacture.

CBRRRT
24-09-2008, 03:36 AM
http://www.streetfighters.com.au/forum/upload/103704465630804.jpg


MZ7 is the right code for the year you need [^]

CBRRRT
24-09-2008, 03:38 AM
http://www.streetfighters.com.au/forum/upload/103704465630835.jpg


M14 is not the code you want[V]

CBRRRT
24-09-2008, 03:45 AM
http://www.streetfighters.com.au/forum/upload/103704465638769.JPG


Hope that helps with the swing arm issue, be glad to share my R1 sub-frame mounting method with anyone thats interested. No welding involved.

Regards

Me and Mini Me

CBRRRT
24-09-2008, 09:20 PM
http://www.streetfighters.com.au/forum/upload/17229484015966.jpg


I need a bit more advice from you guys about the zorst I'm going to fit.

I now have both end cans and the conversion kit to turn them into race pipes, and need to start to think about the 1 to 2 Y connector. the one pictured above is an item available on e-bay for around 50 quid, but it has a cat converter in it.

My question is,

Is there any reason why I cant shove a screw driver down its throte, rip out its guts, and stamp them into the workshop floor, and just have an empty tube connecting my cans to a link pipe.

25-09-2008, 06:18 PM
hi,how u doin,i have a 92 blade with a sswa and a car wheel,the correct swingarm to use is the vfr 750 94-97 swingarm,it must have the lug underneath the swingarm to bolt your fireblade shock to..happy building......

CBRRRT
25-09-2008, 06:31 PM
Thanks matey, I figured that out for myself the hard way lol.

CBRRRT
26-09-2008, 05:13 PM
http://www.streetfighters.com.au/forum/upload/59023877232439.jpg


This is how I got over mounting the the top of the 06 R1 sub-frame....

CBRRRT
26-09-2008, 05:16 PM
http://www.streetfighters.com.au/forum/upload/59023877228595.jpg


This is how it looks in the out side. I painted the head of the bolt that shows to mach the sub-frame, but it will be covered up with the small cover panel I made a couple of weeks ago, and is shown on a previouse photo.

CBRRRT
26-09-2008, 05:20 PM
http://www.streetfighters.com.au/forum/upload/59023877234288.jpg


Got to do a little bit more to the lower sub-frame mounts tonight when I get in from work, but I couldnt resist sticking on the other zorst that came from spairs unlimited today.

I'll stick on some more photos of the sub-frame lower mount when I get them done over the weekend.

CBRRRT
26-09-2008, 06:08 PM
http://www.streetfighters.com.au/forum/upload/59023888630165.jpg


Automotive PORN[:p]

CBRRRT
26-09-2008, 06:17 PM
Any way, I was in the post office the other day, and some guy in a mask walks in with a gun and starts to hold the place up. He shouts at the teller to fill his bag with the money from her desk.

Some have-a-go hero jumps up and pulls the guys mask off and the robber says to him 'You've seen my face' and shoots him dead.[xx(]

He then looked at the teller and says to her 'You've seen my face' and shoots her dead.[xx(]

As he is putting on his mask he shouts out, Did anyone else see my face?

The guy next to me, looks at me and smiles, then shouts back to the guy, ' I think my wife caught a glimps' ;)

fimpBIKES
26-09-2008, 06:24 PM
haha, subtle mate


your doing good there with the swingarm business!

you can rip the innards out of a cat, no worries
but i think you might need something with custom bends to get it looking decent
best to go see your local muffler-guy

CBRRRT
26-09-2008, 08:48 PM
Thanks for the advice mate, I'm going to tear its guts out over the weekend. I have orded a couple of stainless link pipes from ebay and will be giving them to a local welder fabricator to do me a sexy link pipe to connect the blade zorst to the R1. I really like the segmented exhausts they have on motor GP bikes with all the welds still showing, and I think I might go for that style and look.

When the swing arm goes in I will be taking loads of photos, just in case they will be of help to others on the forum, with simmilar ideas.

I have been on a few biker forums, but the guys on here are a top bunch of blokes, and like minded to myself. I have seen some fantastic stuff on here from some really clever people, and real food for thought.

Its a pleasure to be on here.

Thanks for taking time to help me with my question matey, it takes me one more step closer.

CBRRRT
27-09-2008, 08:58 PM
http://www.streetfighters.com.au/forum/upload/79922600938268.jpg


I got the bottom sub-frame mount on this morning, but the paint blistered around the blots, so I think I might need to get the parts powder coated.

CBRRRT
27-09-2008, 09:01 PM
http://www.streetfighters.com.au/forum/upload/79922600939981.jpg


Quite pleased with the little infill panels too. I think when the bike is painted they will tie in the tank to the seat unit quite well.

CBRRRT
27-09-2008, 09:08 PM
http://www.streetfighters.com.au/forum/upload/79922600952172.jpg


I think I have to make a bit more effort to get the swing arm mounted now.

I know its 25mm narrower than the stock arm because I had to have a spacer made up. This will give me about 65mm between the back of the rear sets and the arm to fit my link pipe to the R1 zorst.

Looking at my rear sets they are set into the frame about 6mm from face of rear set to face of frame, so I could pack them out with washers if I have to gain a bit extra space.

CBRRRT
27-09-2008, 10:10 PM
http://www.streetfighters.com.au/forum/upload/79922619014478.jpg


Not sure if this will be of any help to you guys, and I aint no engineer so I cant do those fancy drawings.

Above I drew around my card templates and added the basic information you need to make your own sub-frame mounting plates.

Lets face it if a dip shit like me can do it anyone can. I have no special skills and a very basic workshop and tools, so if you are like me and drool over the bikes the clever blokes on here turn out, take a deep breath get out your hack saw and get stuck in, whats the worst that can happen [B)] lol

CBRRRT
27-09-2008, 10:14 PM
I didnt think there would be any point in putting on my infill panels template, because the shape would depend on the angle you mount your sub-frame.

CBRRRT
28-09-2008, 06:13 AM
http://www.streetfighters.com.au/forum/upload/79922695534053.jpg


Back wheele out with a bunch of other stuff.

CBRRRT
28-09-2008, 06:16 AM
http://www.streetfighters.com.au/forum/upload/79922695535440.jpg


This is the spacer 25mm outside dia with a 20mm hole through it, and 25mm long

CBRRRT
28-09-2008, 06:21 AM
http://www.streetfighters.com.au/forum/upload/79922695537387.jpg


The spacer fits snugly into the right hand side of the swing arm. its easier to hold it in place with a little dollop of cream cheese or KY gel.

CBRRRT
28-09-2008, 06:55 AM
http://www.streetfighters.com.au/forum/upload/79922702213560.jpg


Right, I've had enough for one day. I'm off to get some of this

CBRRRT
28-09-2008, 06:56 AM
http://www.streetfighters.com.au/forum/upload/79922702217927.jpg


And lots and lots of this

CBRRRT
28-09-2008, 06:58 AM
http://www.streetfighters.com.au/forum/upload/79922702227956.jpg


Probably end up with something like this

CBRRRT
28-09-2008, 06:59 AM
http://www.streetfighters.com.au/forum/upload/79922702217927.jpg


But with a bit more of this

CBRRRT
28-09-2008, 07:01 AM
http://www.streetfighters.com.au/forum/upload/79922702216779.jpg


Might end up looking like this.....

CBRRRT
28-09-2008, 07:03 AM
http://www.streetfighters.com.au/forum/upload/79922702210359.jpg


Just hope this is up to it............See you later lads

CBRRRT
29-09-2008, 04:20 PM
http://www.streetfighters.com.au/forum/upload/100826494627734.jpg


Spent all day Sunday having a bit of a tidy up under the seat unit. I wouldnt normally attempt to do wiring but I was bored and who knows what you can do untill you try.

I mounted the Regulator in front of the battery and the CDI unit just behind it.

The imobiliser alarm was a bit of a problem but I eventually put it under the pillion seat.

There was a bit of cutting and soldering to do, but nothing anyone with half a brain couldnt handle.

CBRRRT
29-09-2008, 04:27 PM
http://www.streetfighters.com.au/forum/upload/100826494632824.jpg


It all looked like a pile of guts when I started, but ended up not to bad at all.

I'm well pleased.

HueyonaBlade
29-09-2008, 08:07 PM
Im watching and learning , mate what have you made your fill in piece out of ,where the top sub frame mount is[?]

CBRRRT
29-09-2008, 08:54 PM
http://www.streetfighters.com.au/forum/upload/100826577229155.jpg


Hi Matey,

When I dumped the bike at snetterton race way I had quite a lot of broken plastic.

I cut out a rough shape from a side panel, then got my hot air paint striper gun and gently heated the plastic. It went soft and flexable quite quickly so dont hold it too close for to long.

Then I placed a weight on to it to flaten the plastic out.

I then got a wheetabix box and cut out a template trimming it a little at a time.

To cut the plastic I put a hacksaw blade in my jig saw, but mind your fingers, it gets a bit fiddley. If you cant get the saw blade to cut from one angle, then come out and go in again from another.

I thought it might look a little better with a slight 3D look to it so I used the template again to draw around the bottom then cut a narrow strip about 5mm following the shape of the bottom of the panel, and a little bit up the front.

I superglued the thin strip to the bottom of the panel to double its thickness, then when it was dry used a round back file to get both edges the same.

This done, I then mixed up car body filler and pushed it into the top edge of the narrow strip so when I sanded it it would make a nice smooth curv and round off the bottom edge.

Once I got the panel to where it almost fit, I noticed that the top of the panel, where it touched the tank was pushing it away and not laying back at the right angle. It didnt line up with the seat and seat pad. I got out my heat gun again and warmed up the front top corner and gently pushed the corner out a fraction.

This was just enough to make the panel sit at a better angle.

I had no idea that it would work when I started, but I had a go and it paid off.

The only thing I would highly recoment would be to make it from card first and get it to fit. If you would like any of my templates email me and I will copy them and email them back to you.

Thanks for taking time to read my thread matey, hope it is of help.

Regards,

Jonathan.

Gix11
29-09-2008, 09:57 PM
I really like a good topic with progress and photos. Cheers Jon, nice work.

CBRRRT
30-09-2008, 03:53 AM
Nice of you to say so mate.

CBRRRT
30-09-2008, 03:59 AM
http://www.streetfighters.com.au/forum/upload/11450379432688.jpg


Had to remove the padock stand to take the pressure off the swing arm so I can drop out the shock. Problem was the axel stands were to short. I knocked up a platform out of 50x50 and ply to lift them up a bit.

CBRRRT
30-09-2008, 04:04 AM
http://www.streetfighters.com.au/forum/upload/11450379424298.jpg


Glued some foam pipe insulation to the top of the stands to protect the rear sets. The glue was quite strong smelling......MAN!!! So keep your work shop well vented.

CBRRRT
30-09-2008, 04:08 AM
http://www.streetfighters.com.au/forum/upload/11450379446587.jpg


Started to undo the bolts to drop the shock, then thought it might be a good idea to take a photo so I remember how it goes back together.

I wish my woman was as dirty as that!

CBRRRT
30-09-2008, 04:15 AM
http://www.streetfighters.com.au/forum/upload/14352066727895.jpg


So anyway, the shock is out and needs a bit of doing up, and the next thing to go is the swing arm. [8D]

FIGHTERMC
30-09-2008, 05:39 AM
nice build you have there mate.
the only thing i'd say to you is
be very careful with the Regulator
as it needs cold air hitting it
or the will blow.
blade's are a bitch for this.
had it happen to me and it also happen to a mate
after they were moved.
rgds

CBRRRT
30-09-2008, 05:49 AM
Guy I work with makes a kit he sells on ebay that comprises of a P.C. fan and a few other little bits that help wick the heat from the regulator. I had it fitted to my original sub-frame and its going back on. I did think about the heat from the engin in the position its in but I think its far enough back not to be a problem, (Famous last words)lol.

Good spot though matey.

CBRRRT
30-09-2008, 05:54 AM
Come to think of it Matey, the gap in my frame above my rearset I could fit one of the ram air pipes off a Yamaha or Suzuki.

Food for thought Fightermc, and I like it!!!

CBRRRT
30-09-2008, 05:57 AM
Hmmmmmm...............Scratchy chin. You got me going now Matey!

FIGHTERMC
01-10-2008, 01:11 AM
i also made an earth wire and put it
from the back of it to the battery.

HueyonaBlade
01-10-2008, 11:47 AM
So what are those rear sets off mate?

fimpBIKES
01-10-2008, 12:45 PM
charging along mate!!!

i'd fit a scoop rather than a fan anyday, the less electrics the better if you ask me ;)



that zorst looks like its come together VERY nicely
great work!

Guile
01-10-2008, 01:56 PM
quote:Originally posted by CBRRRT
I then got a wheetabix box and cut out a template trimming it a little at a time.
its called wheet-bix here mate and its half the size of wheetabix, go figure

anyway just thought i'd say great project, its coming along nicely and will be sweet when its finished

CBRRRT
01-10-2008, 04:36 PM
Thanks lads,

The rear sets came of ebay, they were a best offer price of £99.00 about $213.00 but I had to pay another £33.00 P.P. and £26.00 Customs inport tax.

I like the idea of a scoop and I think I will be going with a scoop off some kind of ram air system.

My Baffles arrived yesterday so I will be posting a few how to do photos of my zorst makeover soon.

Thanks for taking an interest lads.

CBRRRT
01-10-2008, 05:12 PM
If anyone on here is interested in rebaffling their R1 zorst then follow the link to ebay below. I had a chat with the guy on the phone yesterday and he said he sends lots of them to Oz.

http://cgi.ebay.co.uk/YAMAHA-R1-04-05-06-END-CAN-RACE-EXHAUST-BAFFLE-KIT_W0QQitemZ320306293939QQcmdZViewItem?hash=item3 20306293939&_trkparms=72%3A1301%7C39%3A1%7C66%3A2%7C65%3A12%7C 240%3A1308&_trksid=p3286.c0.m14

Dont forget to hit the youtube link on his page, its quite cool.

01-10-2008, 06:40 PM
hi mate,i would have to agree with fighter mc,the rectifers are dodgy,i went through 10 of them.If i was u i would get the electrexworld replacement and junk the origional.......www.electrexworld.co.uk

CBRRRT
01-10-2008, 07:33 PM
Top tip Griff, I'm on it.

Thanks Mate.

CBRRRT
04-10-2008, 11:32 PM
http://www.streetfighters.com.au/forum/upload/97931139714942.jpg


Anyway I am having a bit of trouble finding the right socket to undo the swing arm nut, so I'll come back to it when I get hold of one.

I thought this weekend I would have a go at ripping out the guts from my zorst.

CBRRRT
04-10-2008, 11:33 PM
http://www.streetfighters.com.au/forum/upload/97931139720529.jpg


Hmmmmm Baffeling

CBRRRT
04-10-2008, 11:35 PM
I guess the first thing to put on my bench would be some protection

CBRRRT
04-10-2008, 11:37 PM
http://www.streetfighters.com.au/forum/upload/97931139722837.jpg


No, not that kind of protection!!!

CBRRRT
04-10-2008, 11:39 PM
http://www.streetfighters.com.au/forum/upload/97931139717595.jpg


Something to prevent your zorst from getting scratched during the [u]Operation</u>.

CBRRRT
04-10-2008, 11:40 PM
http://www.streetfighters.com.au/forum/upload/97931139716111.jpg


OPERATION?..........I'LL DO IT

CBRRRT
04-10-2008, 11:42 PM
http://www.streetfighters.com.au/forum/upload/97931139717355.jpg


First lay the zorst on the protection and drill out the pot rivets with a 6mm drill bit. Anyone with a stammer wil need a 6mmmmmmm drill bit.

CBRRRT
04-10-2008, 11:44 PM
http://www.streetfighters.com.au/forum/upload/97931139716012.jpg


Once they are all drilled out you will need to knock out old rivets in with a punch

CBRRRT
04-10-2008, 11:46 PM
http://www.streetfighters.com.au/forum/upload/97931139712943.jpg


Take off the end of the zorst and this will expose the spot welds

CBRRRT
04-10-2008, 11:49 PM
http://www.streetfighters.com.au/forum/upload/97931139715270.jpg


Wrap 19mm electrical tape around the end can and this will give you your cut line. 19mm is very important as this will sit right with the new baffle, when the end is pot rivetted back on.

CBRRRT
04-10-2008, 11:53 PM
The next thing to do is carfully cut to the line of the tape with your hack saw. I did it on my own and found it a bit awkward, so if you have a mate, or a nurse to hold it for you.....THE ZORST.....for fuck sake consentrate, or we will never get through this. Any way get a mate to hold the zorst for you so it wont move while you are cutting it.

CBRRRT
04-10-2008, 11:55 PM
http://www.streetfighters.com.au/forum/upload/97931139720588.jpg


Slide the old baffle out........OH MY GOD, I CAN SEE ITS INSIDES.

CBRRRT
04-10-2008, 11:57 PM
http://www.streetfighters.com.au/forum/upload/97931139755299.jpg


I think I'm gonna be sick.

CBRRRT
04-10-2008, 11:58 PM
Anyone with a weak nature should leave the room now!

CBRRRT
05-10-2008, 12:00 AM
http://www.streetfighters.com.au/forum/upload/97931139721506.jpg


Now take a craft knife and cut through the thin wadding around the old baffle

CBRRRT
05-10-2008, 12:03 AM
http://www.streetfighters.com.au/forum/upload/97931139730758.jpg


If it has the same blood type as the new baffel you need to remove it from the old baffel and cut it so it wraps around the new baffel once.

CBRRRT
05-10-2008, 12:04 AM
http://www.streetfighters.com.au/forum/upload/97931139732829.jpg


Like this

CBRRRT
05-10-2008, 12:07 AM
http://www.streetfighters.com.au/forum/upload/97931139736010.jpg


Tape it to the new baffle like this. The tape will burn off after a while, but it wont matter because the steel wool wadding will hold it in place.

CBRRRT
05-10-2008, 12:09 AM
http://www.streetfighters.com.au/forum/upload/97931139723398.jpg


Next file off any jagged edges from the end you cut, so the steel wool wont snag when you are repacking the zorst.

CBRRRT
05-10-2008, 12:12 AM
http://www.streetfighters.com.au/forum/upload/97931139730381.jpg


Cut off steel wool about 200mm strips. I found it was easier to split the wool in half to get it round the inner baffel.

CBRRRT
05-10-2008, 12:16 AM
http://www.streetfighters.com.au/forum/upload/97931139720105.jpg


Next thing to do is put the baffel into the can and make sure it is located over the lip at the bottom of the can, its very important that you check it is over the lip, and the right way round, as the end of the baffel has a slanted cut on it. when you put on the end cap it will still move a bit so you can adjust it to fit. Once you are happy with the above start pushing the steel wool down and around the baffel.

CBRRRT
05-10-2008, 12:19 AM
http://www.streetfighters.com.au/forum/upload/97931139753260.jpg


I used a hack saw blade to push down the wadding. Its hard to say how tight to pack it, but just dont force it. Tight but not compacted.

CBRRRT
05-10-2008, 12:21 AM
http://www.streetfighters.com.au/forum/upload/97931139719891.jpg


Once filled try to do a rough moulding of the outside of the end cap so it fills to the end.

CBRRRT
05-10-2008, 12:24 AM
http://www.streetfighters.com.au/forum/upload/97931139737160.jpg


Slip back on the end and make sure it is pushed right home and not wonkey. Then drill a 5mm hole and pot rivet it.

CBRRRT
05-10-2008, 12:27 AM
http://www.streetfighters.com.au/forum/upload/97931139720336.jpg


Continue all round untill all the holes are refixed and and clip off any loose steel wool pubes.