Jim's ZXR750 Build

[Nudie]

Holey crap! Is that straight through, or is there some baffling in the mid pipe?

[JimZXR]

Exhaust fitted, test ride done, HOLY SHIT that thing is loud now!

But the shortened exhaust has really helped the motor as it feels so much more free revving now than before.

Will have to do something about the exhaust but will see what I can think of!

No mid pipe Nudie, all straight!

[LKC73]

Exhaust fitted, test ride done, HOLY SHIT that thing is loud now!


No mid pipe Nudie, all straight!

FARK!!!! that would be ear splitting at full song!!!!
Those jardines are loud on late model bikes with Cats still on the systems, hate to hear it on that pipe lol.

[Gix11]

I rode full open once and it's just mental. Cops would be all over you around here if you tried it. Might want to come up with something. Bet it looks great on though hey?

[JimZXR]

It has a "baffle" of sorts in it but gonna get a perforated sleeve baffle (not dissimilar to the internals of a standard pipe) put into it to help bring the noise down a touch.

[BOBBY]

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Here's my straight pipe. It has that perforated shit in it. I jammed a washer in it also to silence it. Finally fitted a staintune bung in it and it just wouldn't come down to an acceptable level. It was ear plugs in when riding at all times. I changed it out after a week I just couldn't handle it.

[JimZXR]

Yeah, I'm looking at a baffle for Harley straight pipes tomorrow and wrapping that in exhaust stuffing to se of it brings it down a touch more.

Can see it being changed out to be honest but for the moment we'll see how it goes.

[BOBBY]

Pretty sure it being an open pipe with zero back pressure fucks with your jetting too. My bike revved easier but the bike felt slower.

[hooligan]

It's not just a straight pipe- it has a small baffle for back pressure. Unless Jim's taken it out.
When it was on the vfr it ran better with the baffle.

[JimZXR]

So I bought a pair of universal baffle pipes and a load of exhaust matting today and did a "dry fit" into the pipe (basically put together what I think I need them to be like, wrapped it in exhaust mat and taped that on) to see how it sounded and have to say it made a big difference compared to the open pipe with the other baffle in it so guessing a combination of them all together will further quieten it when I've got it properly fitted and whatnot.

Will post some pictures and videos (have to figure that out) when I've don't the work to it.

[JimZXR]

Things are moving on well with the bike now as a mate has been in touch and my shortened rear subframe is tacked together and ready for a dry fit to the bike!

Can't wait to get it fitted and see how it looks.

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[JimZXR]

Exhaust 99% done, just need to make a hanger bracket.

Got the subframe fitted and am happy with the position but need to figure out the tail unit or plastics. Anyone got any pearls of wisdom for plastic remoulding and welding?

[JimZXR]

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[JimZXR]

Tubby bastard on a barely finished fighter; I know, but fuck it, its mine and I'm killer happy!

[BOBBY]

It's got good lines as is. Nick76 done a killer job on the tail on mine using a standard subframe.
Can't wait to see what you do with it.

[LKC73]

Got the subframe fitted and am happy with the position but need to figure out the tail unit or plastics. Anyone got any pearls of wisdom for plastic remoulding and welding?

Maybe not a pearl of wisdom but you best bet is to find a tail unit in which your happy with.
Also, you maybe better off finding something in fibreglass as it is a bit better to work with than plastic is.

[JimZXR]

So after a little trial and error I've managed to remould the OEM plastics to kinds the shape I'm after and I'm pretty happy with the mock up results so I'm gonna give it a go with my good set.

Will add some photos once it's done but I'm pretty hopeful it won't look atrocious!

[JimZXR]

DONE!!!

Tonight I've finished mounting the exhaust bracketry, fitted and filled the the coolant reservoir and managed to get the tail fairings remoulded and chopped into something like the shape I want now theyre cooling down with a few screws securin them in place until I can get them finished.

Photos to follow tomorrow.

[Gix11]

So where's the photos!? The suspense is killing me!

[JimZXR]

Can't upload photos from my iPhone, have to upload from computer which is at work!

[Yella]

How did you go with exhaust.?

[JimZXR]

Removed one of the baffle tubes and matting, retightened the header clamps and gave it a run out and it was much better but still lacking power and torque so gonna remove all of the baffles and see how it goes. Failing that I'll change back to my old system and if it is back to normal with that on I'll have to find another can to make that system look how I want or shorten the can I have.

[JimZXR]

Turned out to be a HT lead; fixed that and all good again!

[JimZXR]

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[ozzy1100]

now that's a cool bike to hoon around on :-)
zip ties rule lol

[rod185651]

I love the look of this build

I rode to Ben's once with the entire subframe on the wretched held together with zip ties.

[BOBBY]

That's bang on Jim. Any plans on making that permanent?

[chinski]

fuck yeah man shorter tail is the goods, looking sweet !!

[JimZXR]

Thanks for the big ups, glad it's taking shape well now.

Plan now is to get the subframe welded solid by a mate then use a plastic welding kit and a load of spare ABS I've got from the experiments to seal the gaps up then reinforce the whole thing from the inside with epoxy and wire mesh/fibreglass sheet.

No doubt It'll need a load more shaping with a heat gun before I'm happy with the shape and fit but overall I'm in a good place to move forward now I think.

Mechanical wise I'm still gonna persist with trying to bring the DB of the exhaust down using baffles and exhaust matt without killing the power too much.

Belly pan and undertray will need to wait until the tail is sorted but they're on the shelf waiting for some attention.

After that it'll hopefully be time for paint or even plasti-dip. Not sure if I'll go Green or Black yet but gonna try to leave the mask paint well alone.

[Gix11]

Good stuff Jim.
Can I just give you one piece of advice with the tail mate? You mentioned welding and fibreglass in the same sentence, which would indicate to me you might be thinking of bonding plastic together with fibreglass inserts. Can I just save you hours of time and disappointment by letting you know that the two do not play well together. I learnt the lesson the hard way a LONG time ago. Although they set hard and look great when done, within about 2 weeks you will start to see cracks before it starts to fall apart. The stress and strains of a moving vehicle break the two apart as they were never really meant to bond. Works fine on a static piece of art, but not a motorcycle!

[The Phantom]

Agreed, plastic welding is the only way to go.

I have this kit and can recommend it. Useful for all sorts of repairs.

https://www.amazon.com/Polyvance-5700HT-Airless-Plastic-Welder/dp/B00IEX6NME

http://www.polyvance.com/images/products/5700HT-1.2.jpg

[rod185651]

As everyone above have stated, plastic and fiberglass do NOT bond. Plastic welding is the go.

[JimZXR]

OK, thanks for the heads up guys, Plastic welding it is.

I may still use some exposure on the inside to add strength to the weld or is that a no-no also?

[Gix11]

Exposure? Did you mean Epoxy? Either way, stick with the same medium and build it up with plastic behind if you want more strength.

A proper weld done right should be enough though.


https://www.youtube.com/watch?v=Uzoyf2xVIuY

[JimZXR]

Will do.

Mrs bought me this kit from Bunnings to start the welding off with so hopefully it'll do the job.

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[rod185651]

in the past, I've used bits of old cutoffs and a soldering iron with successful results

[hooligan]

Me too.

[rod185651]

One of the benefits of building a fighter heaps of plastic left over to use for welding

[Goodtime]

That thing looks slick! I like it. Always likely the semi retro look of those things!

[JimZXR]

Definitely have plenty of plastic left but gonna try to use most of it to make the remaining panels but any off cuts will definitely be melted on!

[BOBBY]

Just throwing this out there Jim but I reckon for the paint if you painted it the original colour with the original graphics modified to suit that tail and belly pan I reckon that would look nuts. Would have everyone asking wtf is up with that ninja.

[JimZXR]

Fair point and not something I haven't considered either.

[The Phantom]

Just to show some plastic welding I've done - see the "Z" at the bottom of the fairing? That's a Blackbird fairing that was about 3" too long for what I wanted to do with it, so I cut and welded it and then tried to break it - no chance.

I cut/welded it as a "Z" because a straight cut/weld would not have the same strength.

I'm currently in the process of plastic welding the CBR1100XX side fairings to the CBR600F nose, more on that later (yes it will still be a streetfighter, but as I also want to occasionally run my custom bodywork I need to get both right before I lock the hardware in for either option)

https://c1.staticflickr.com/1/668/22712147043_bd9875d6d9_c.jpg

[hooligan]

As long as your bike is up and running before phantoms is, Jim.

[JimZXR]

Phantom; that is killer work!

Hooligan; I make no promises!

As for paint I'll be having a crack at it myself with the remaining paint from my track bike build a while back which ran the same colours as the road bike.

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[The Phantom]

As long as your bike is up and running before phantoms is, Jim.

I think Jim is safe there :)

[JimZXR]

Had a crack at plastic welding some spare pieces last night to get my eye in and see what kind of heat and time the weld needed and I'm well happy with the results!

The piece I welded was very strong to the touch today when bended and after a bit of sanding I'd say it'd be just the job.

Now I'm looking for an original ZXR750 seat cowl to shorten and make suit my modified rear end.

Only thing that's stumping me at the moment is how to get it to latch; any advice or should I look at fixing it on solid?

[JimZXR]

I know it just a simple weld line of two junk pieces but it's shown me what can be achieved with very little prep.

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[Gix11]

My cowl is bolted on with 4 allen head bolts! No pretty awards at my end. Does the job and I never need to get under there anyway.

[JimZXR]

Slightly off subject but I've got the chance to add some entertainment to my garage as my cinema kit has started not playing DVDs so it's surplus in the living room and I've managed to talk the Mrs around it going in the garage to keep me company! I'll use my iPod to get music through it so no need for CDs either!

6 speakers banging tunes while spannering on the bike should be awesome!

[rod185651]

Do you still play DVDs? Very retro Jim.

[The Phantom]

I upgraded my home cinema gear and relocated the old Wharfedale satellite/subwoofer combo to the workshop - nice to have quality sound while you work!

[Gix11]

Do you still play DVDs? Very retro Jim.

This statement comes up quite a bit. Just curious Rod, what is the new normal then? Are people just streaming low res videos online instead?

[JimZXR]

Do you still play DVDs? Very retro Jim.

Best thing for the kids we find otherwise they start downloading one, get bored, download another, etc and it killls my download limit too quickly!

[The Phantom]

I still watch DVDs. My only internet is my work connection via my work supplied laptop, so no go there - I do abuse it, but I'm careful not to go too far :) Movie downloads are out.

Also my kids (between 9 and 13) and I quite enjoy the ritual of the DVD night... everyone helps cook dinner, we eat, we find our happy places on the lounges, and we hit play. Once the movie is happening it's time to get icecreams out of the freezer.

I also like carburettors :p

[JimZXR]

I still watch DVDs. My only internet is my work connection via my work supplied laptop, so no go there - I do abuse it, but I'm careful not to go too far :) Movie downloads are out.

Also my kids (between 9 and 13) and I quite enjoy the ritual of the DVD night... everyone helps cook dinner, we eat, we find our happy places on the lounges, and we hit play. Once the movie is happening it's time to get icecreams out of the freezer.

I also like carburettors :p

Sounds like our house!

[JimZXR]

Got my tail fairings ready for cutting so hopefully restart the shaping then welding soon.

Gonna try to get a rear seat cowl to copy or chop to fill in the gap behind the riders seat while still keeping all of the original mounting points.

Have to say though I'm loving the plastic welder, probably saved myself over $100 so far by fixing plastic stuff like our bin!

Progress and pictures to follow soon chaps!

[Gix11]

Nice one. Cheers mate!

[rod185651]

This statement comes up quite a bit. Just curious Rod, what is the new normal then? Are people just streaming low res videos online instead?

For music I use Spotify premium now. Just about every band is on there except for Tool. It is only about 10 bucks a month.

For TV and movies I download from the internet and watch through Plex.

[Gix11]

Cool. Cheers Rod.

[JimZXR]

Not really an update but took a quick ride out tonight and have to say the headlight and mask combination gives good enough light to ride at night but may have to lower the beam a touch but otherwise happy.

[JimZXR]

Managed to get some time in the garage today due to the rain and got a good start on the tail unit.

Cut throigh the part I'm reshaping to make strips the started reshaping the individually and cutting off the excess, which it turns out can be done with just scissors if the plastic is hot enough.

Now I'm getting the general shape sorted I've got to do some more trimming then I can start to do the welding.

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[JimZXR]

F*cking upside down photos!

[LKC73]

F*cking upside down photos!

Upside down Miss Jane!

[JimZXR]

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[LKC73]

Looks like you'll be having a lot of fun plastic welding it mate. Keep us posted on how it all goes hey. I cant wait to see you finish this thing.

[The Phantom]

That is certainly a different way of doing it - different to how I think, at least. That's what I love seeing here :)

[Gix11]

Wow, this is going to be interesting.

[JimZXR]

I know what I'm doing looks very daunting but there's method to the madness; I couldn't reshape the original plastics from their former shape into what I wanted by the virtue of that original shape not wanting to conform as there was too much or too little material in places and no way to lose it efficiently without cutting it so I decided to take it down into smaller pieces so I could shape them one at a time and make more incremental adjustments rather than trying to make a large piece move a small amount and deal with whatever changed elsewhere to compensate.

I'm confident (famous last words) I can get it somewhere near what I need and then by sanding and shaping what's left I can make it work. Plus I'll lay plenty of weld on the rear of the panel to make it solid again.

More shots to come; failure or not!

[Gix11]

Good on ya mate, I love the spirit!

[LKC73]

Jim, How's his going mate?

[JimZXR]

Terrible!

Tail fairing has been disaster! So I'm now looking for a reasonably priced fibreglass unit to put on then have someone weld me up a subframe.

[LKC73]

That sucks to read Jim. Hit me up if you need a hand welding up a subframe. As for fibreglass unit, if you can spare the coin buy one you like from this guy.
http://www.ebay.com.au/itm/PleiadesCustomz-Universal-Short-Streetfighter-Seat-Tail-Unit-sitz-Fairing-/252888948716?hash=item3ae15b1fec:g:mdAAAOSwBLlVXPI p
Not bad gear and a decent price.

[JimZXR]

Already way ahead of you with PleiadesCustomz tail unit!

I prefer this one but not sure how the knuckles will go down with cops!

https://www.ebay.com.au/itm/252909264811

[JimZXR]

In fact I just buckled and bought one!

Seems I may yet be calling for some assistance with a subframe LKC73!

[JimZXR]

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[LKC73]

Hell Yeah! don't worry about the dusters, that will be the least of your worries mate.
Give us a yell when you need a hand.

[JimZXR]

Fuel pump bought (last one shat itself), seat unit on its way, searching for a new can (any offers?) and hoping to get the subframe design started soon; things are again moving along!

[Gix11]

Good news Jim. Keep it coming!

[LKC73]

Fuel pump bought (last one shat itself), seat unit on its way, searching for a new can (any offers?) things are again moving along!
Jim, have a look at the black widow exhaust site in the UK. Not badly priced.
I look forward to your updates.

[JimZXR]

Wow; seat unit is already here!

Have to say that although it looks awesome it's definitely built for a narrower arse than mine! May go for the adult size next time!

Gonna strip back my OEM subframe and harness then offer it up and see what's what; pictures to follow soon.

[JimZXR]

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[Gix11]

...and so it begins. Sub frame time mate.

[GammaBoy]

Is that meant for a Pocket bike?

[JimZXR]

Looks like it ey!

Thinking it may be more suited to a slabby Gixxer frame than mine.

Not certain yet but it may be back to the drawing board!

If so there may be a members competition prize coming your way Gix11!

[LKC73]

Have to say that although it looks awesome it's definitely built for a narrower arse than mine!

This is why I have bought a race tail for my R1 and will be merging the fighter tail onto it. My R1 has an even fatter arss due to the untail pipes. But there is a way Jim, and I've done it before on a café style tail.
I'll share pictures when I get home later tonight.

[JimZXR]

Just seen the update on your thread LKC73, looks mega.

I've got the tail section of my OEM subframe away being welded by a mate to shorten it up before I start to trim back the internal plastics to move the battery to the very rear and tidy up what's beneath the seat so I can still have some storage space whilst tightening up all of the wiring.

Bought a load of expandable foam, builders plastic and a few other bits so I can start to built the plug for my one off tail unit.

Hopefully soon be ready for some resin and fibre sheets then the big question on how it'll actually come off and back on again!

[LKC73]

What are you doing with the fibreglass one you bought?
Didn't you want that one now?

[JimZXR]

So I've bought an exhaust pipe spreader to open out my exhaust pipe to fit my headers and am still waiting for the replacement fuel pump I ordered to arrive, once there here I can try running the bike with the tank on and see how loud the new pipe is and if it needs any or more exhaust matting.

On the subframe side I've decided to have the two halves of the subframe welded together solid as before I was considering having the as a removable section. Once that's back I can trim up the underseat plastic section to move the battery to the rear of the bike near the tail light.

I've also removed the old brake fluid res so it can be replaced with something less obtrusive.

[JimZXR]

Fuel pump has arrived and is now fitted.

Just waiting for a mate to get back from a cruise so I can get my shortened subframe back and get the battery installed so I can fire it up again!

[JimZXR]

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[LKC73]

Its stripped! :cool:

[JimZXR]

Exhaust update; total, complete and utter failure! After opening out the pipe I've discovered its internal bore is way too narrow for my bike and it's choking it really badly.

Short term I'm going to refit the original headers and Tingate pipe I had in then deal with te aesthetics at a later date; just want it running for now!

[LKC73]

That's a shame Jim, but its the way with customs bikes. Trial and Error, some days more errors than wins. hang in there mate.

[JimZXR]

Thanks mate. I'm not too numbed out as I've always liked my original pipe but the thought of chopping it does bother me a bit so I'm definitely gonna look for something else to mod for the look I want.

[JimZXR]

This one...

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[JimZXR]

Got my subframe lack from being welded so I can start the setting out of the custom tail unit and do any more subframe trimming that's needed to clean it all up.

Pictures to follow....

[LKC73]

Good one Jim, look forward to seeing how this works for you.

[Bob]

Noice

[JimZXR]

Trimmed a few unneeded tabs and brackets off the subframe earlier, just have to sand it back to smooth off what the grinder didn't get.

Once I'm happy with the subframe finish I'll block out the gap with cardboard, mask/sheet off all of the parts I don't want to cover in expanding from then start spraying and layering it on.

Hoping to grab some photos as I go and get them up here.