Jim's ZXR750 Build

[CK 187]

Also, have you considered making a gel coat mold rather than a resin unit and trying to dissolve your foam? It's far easier than it looks. Just takes the extra step of the gel coat

[Gix11]

The HD foam would have saved all this part with the bog mate, that's why I suggested it. Your determination is strong though and I admire your persistence.

[JimZXR]

You live - you learn!

[Gix11]

Need a LIKE button!

[JimZXR]

Top idea Gix!

Back onto the build though...

I've "obtained" a large heavy bastard file from work and will be attempting to take off the heavy excess of filler and maybe get back to the shape I want but almost needing to get another set of critical eyes onto it to point our place a it needs to rise/fall/lift/drop that I can't see; any takers?!?

[Gix11]

Photos? Can we see it from some photos and help that way?

[JimZXR]

Considering my record with upside down photos isn't the best I decided to have a mate pop over to give me some guidance by eye and I've taken a little off here and there, got it down to smooth again and painted white so I can see the marks I've made beneath, now I'm thinking another light skim of filler and hopefully a last sand before I can filler prime and flat before giving it a light coat of green (good coverage and of course, Kawasaki) and clear then hopefully on to making the mould.

Luckily a Pal at work has offered to help out and is adamant we should make the final product from carbon rather than fibreglass so might yet have. Scar on tail unit! It'll be getting painted but I'll be really happy knowing its carbon underneath. May have to clear it guitar then mask of a section to prove its carbon underneath but it could easily look shit so we'll see.

[JimZXR]

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[JimZXR]

Fuck!!!

[JimZXR]

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[JimZXR]

More fuller applied!

Starting to hate this now!

Plus side Mrs ZXR has agreed to my financial estimates so the party can continue!

Bought a new can in the recent eBay sale which should arrive around the same time as my new fuel pump so looking positive!

[JimZXR]

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[rod185651]

New exhaust?

[JimZXR]

Yeah, I have a ZX9 header on it with the balance pipe removed but I'm wanting a low exit pipe to suit the look of the bike more and the one I got from Hooligan makes it basically straight piped and attracts too much attention.

Hoping the pipe above will help to drop the DB down a little more once it's fully packed with exhaust mat and a DB killer

[LKC73]

Jim, I know your starting to hate this process, but hang in there. Its going to look killer once you have it done.
New pipe look good too, it will reduce the DB and should create a deeper note to it.

[JimZXR]

So after a few hours more sanding here and there and a few more kilos of filler (literally) I've managed to make a huge stockpile of filler dust and what looks like one finished tail unit plug maybe ready for a mould.

Now I'm wondering if I can take out some imperfections from the plug in the finished item or does it have to be perfect?

[JimZXR]

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[JimZXR]

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[kev@vcm]

Killa build mate loved reading all of it will be glad to help make the seat look sweet for your beast

[GammaBoy]

Plug has to be perfect I'm afraid bloke.

[Gix11]

Yep, what Gamma said.

[JimZXR]

To explain my feelings on receipt of this advice I shall merely say; FUCK!

[JimZXR]

On a plus note my pipe arrived today!

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[JimZXR]

Fuck these iPhones bad their stupid upside down photos!

[rod185651]

Exhaust looks sweet mate :-)

[JimZXR]

Yeah but it's already sat against the swingarm so thinking I may need to either hammer a reveal into it or have the end of the manifold moved over a touch?

I'd say it'll be mega loud still so thinking a DB killer will be a must.

[badboynot]

Looking good jim! As always check up and see your still at it,I should go a new muffler or something to make my self like my bike again.keep at it even if it's only small bits hire and there! Looks good

[JimZXR]

Cheers man, came to the realisation the other day that I have to cut into my tail unit to clear some material from the subframe which is poking through now so that seriously sucks balls but I'm determined to see it running again!

Will be back online again soon with an update as soon as I get rid of the Monster-In-Law in a few weeks!

[JimZXR]

A bit of therapeutic hammering today has worked out my swingarm/can fouling issue!

[JimZXR]

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[rod185651]

No clearance to swingarm?

[JimZXR]

About 5mm clear now I've made some adjustment to the can using a heavy rubber mallet and a 36mm impact socket as a dolly!

I admit it's not pretty but the indent is completely hidden by the swinger so I'm happy enough.

Cleaned out and refurbed my fuel tap too as it was clogged now need to open up carbs for a look and see if anything's in there.

Fitted the new fuel pump too so it's moving forward again but I still need to hack at my seat unit so not looking forward to that bit but hey how!

[JimZXR]

Another view but still not great; I'll get one with it on the bike and try to show the clearance to the swinger it now has as it was pulling the header over previously it was that tight.

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[Gix11]

Well, that's one way of doing it! :) If it works, is unseen and you're happy, then that's a win.

[LKC73]

You sure sorted that out with the pipe Jim. Should be ok sound wise. Did you get a DB killer with the can? maybe compare sounds with and with out. Bummer about the tail though, but again, you'll work it out.

[JimZXR]

No DB killer unfortunately but I'll grab something off eBay if it's still too much.

[rod185651]

Can you flatten the entire side to the one depth so it doesn't look like accident damage?

[JimZXR]

I could Rod but I'm not that bothered to be honest as it's completely hidden by the swinger when it's installed.

[rod185651]

Sweet! True streetfighter style

[JimZXR]

Changed plugs, test fitted new battery and got wiring back in place.

Hangs Oil tomorrow then hope to fire it in the evening and potentially squirt it round the corner quickly.

Tail unit is being prepped for some Dremmel surgery but hope to get some more progress with filling and sanding after Sister-In-Law leaves us next week. She's not dying; just travelling back to UK!

[JimZXR]

Put battery and tank on, turned on fuel and a few turns later with a little choke she fires happy as!

The new can is quite loud but nothing like that Jardine so I'm well happy. Took it for a quick squirt and it's hesitating a little but nothing a trip to Dr. R1 won't fix (I know it's a Kwaka but he's a mate and I trust him)!

[LKC73]

Took it for a little squirt and it's hesitating a little but nothing a trip to Dr. R1 won't fix (I know it's a Kwaka but he's a mate and I trust him)!

That's the ticket mate, Good work. Dr R1 just finished a R1 fighter build I seen.

[LKC73]

Hows the bike going Jim?

[JimZXR]

It's heading to Terry (Dr.R1) on Friday after work.

[JimZXR]

Slight change to plans due to the weather; bike heading rob dr.R1 on Saturday morning but I've decided to ride it there and get a feel of it before I give it over for settling!

Got the pipe fitted on good and tight last night now just need to cut some aluminium plate to make a bracket then she's good.

Tail unit still needs work so gonna do some Dremmel surgery this weekend before hopefully one of the last layers of filler then just spray putty and primer.

[JimZXR]

Made the exhaust bracket from a snallnpiece of 3mm ally plate and bolted it up last night and she's solid.

Put the old tail back on and waiting for my slot at the mechanic so I can drop it off for tuning.

[JimZXR]

After the ride to Dr.R1's I can say that even before the carbs are balanced and synced the bike feels amazing once it's up and singing.

Lifted the front with no effort and pulled really well through the gears.

Will need a clutch in it soon as it slipped between 2nd and 3rd at the top end but that's an easy job and forces me to do an oil change too.

So happy with the comfort and feel of the bike now.

This photo is unfortunately with the original subframe as the custom tail still isn't finished.

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[LKC73]

Looking cool and sounds like Dr R1 will have an easy time sorting it out.

[GammaBoy]

Hey dude, can you put a tape measure across the width of the radiator for me?
Cheers.

[JimZXR]

No worries gamma, will do when I get it back.

[GammaBoy]

Cheers!

[rod185651]

This photo is unfortunately with the original subframe as the custom tail still isn't finished.

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Very cool, has indicators? brake lights? number plate? yep, I can ride it over.

Respect

[JimZXR]

Yeah; the brake light, plate and indicators are from its former persona! Only thing carrying over will be the plate a set I also have a new integrated light for it too.

Will keep the indicators and plate bracket for if I ever get issues from the fuzz!

On a different note; FFFUUUCCCKKK!!! I've had the short tail in my vice to "gently cut away some exposed subframe aluminium" and decided after my Dremmel was taking too long that I'd give it a go with a cutting disc on my grinder! Results are as expected!

I now have a tail unit with side fucking windows! Could come in useful but doubt it so I'm back to big and sanding AGAIN!

His tail had bestie worth it or I'm gonna be significantly unimpressed!

[JimZXR]

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[LKC73]

LOL dude, how in the world did you do that? Oh well, fill it, bog it, sand it and keep ya head up, you'll get there.

[Gix11]

Seriously mate, I'd be getting the High Density foam now before you spend another 10 years on this one. You could use that tail as a model to shape the foam and you're done! Sanding foam is like shaping butter, you'll save your sanity as well.

Here's some vids of a guy making a tail from foam.


https://www.youtube.com/watch?v=MAinuf5I_dw


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


https://www.youtube.com/watch?v=ZIXfZe3hCL4


https://www.youtube.com/watch?v=yfzwRaIJf0c


https://www.youtube.com/watch?v=6wvRfuSW9UI

[ozzy1100]

Great vids si

[JimZXR]

Yeah, I watched those already Si but the issue I think I'd have is that I'm not starting from a similar lay in shape like a cage seat I've got an all round shape to mine which would mean somehow gluing the HD foam blocks together and making the shape work either on or off the subframe which would be a nightmare!

I will admit it does look appealing but I can't see how I'd make it work for me without some serious pain in getting the lines and shape right while still making to work with my original OEM shaped parts.

I'm completely open to advice or guidance on that one if anyone can help?

[JimZXR]

On the plus side I've already heard back from Dr.R1 and the motor in my bike is top notch on leak down and compression tests.

He's saying it looks like it running lean on 1, 2 & 4 but rich on 3. Needs proper block offs making up for it too so I'll start looking at that tomorrow.

[LKC73]

The issue is, you are on a budget hey Jim. Because a race tail would be the go and do a similar process as I did to the R1.
Race tails tend to be alot easier base point as there are already fiberglass so you can cut and shunt them as much as you like.
This was you'll get your OEM lines, but have the ready made shape in fiberglass.
I'm sure you'll be able to locate a second hand one around somewhere. Wont matter about condition, cos your chopping it up anyway.

[Fish]

Great vids Si. I'll be paying close attention to them soon.

[JimZXR]

A race tail is still an option but I was really wanting to make something totally one off that's why the foam was so appealing.

For next time I'll definitely consider a "cut&shut" tail unit made from another race tail or using the HD foam for something with a more custom feel. Still not quite sure how I'd go about making a HD foam plug fit perfectly into my original subframe but hopefully someone can show me the way as it sounds promising.

[LKC73]

Still not quite sure how I'd go about making a HD foam plug fit perfectly into my original subframe but hopefully someone can show me the way as it sounds promising.

It wouldn't be all that difficult to be honest. You'd just have to measure where the mounts are and make sure the width and distances are right. Hard for me to explain in writing but in practical terms its just easier to show you. Not only that, but once your tail unit is made, you can always add on to the inner side to get the contact points you want to mount it.

Doing a plug style tail means you are open to all and anything you want and not restricted to any boundaries.

[JimZXR]

Had to get the main fuse and holder replaced as it was causing a really bad misfire so got a little bit longer to get it fully sorted so it's on to the tail unit AGAIN!

[Gix11]

A true battler! Get in there mate; you'll get it sorted eventually.

[JimZXR]

Got to work with what you've got Gix and since I'm short on skills I'll just turn up the enthusiasm!

[LKC73]

Got to work with what you've got Gix and since I'm short on skills I'll just turn up the enthusiasm!

Like I said man, if you want some help I'd be happy to call round on a weekend or 2 to help.

[JimZXR]

Bought 2m of carbon fibre twill sheet and plenty of resin so all being well I could be moulding by next weekend!

[JimZXR]

Like I said man, if you want some help I'd be happy to call round on a weekend or 2 to help.

I think I'll be taking you up on that offer mate, just let me get the plug sorted and set myself up before I book anything in

[LKC73]

No worry's Jim, when ever your ready.

[JimZXR]

Just to be clear with everyone I've had a slight change of heart:

After watching the YouTube videos posted a few pages back and discussing the job with a work colleague who makes boats in his spare time I've decided to not make the mould from this unit and make a truly one-off seat unit instead by laying the carbon over my plug then after it's cured remove the plug from the inside by melting it with acetone.

As far as making another seat unit I'll be making an attempt using the HD Foam (as advised by Gix) once I have gotten over this current seat unit debacle!

My work colleague is confident I'll be able to make the seat unit work with just two layers of carbon on the outside then building it up inside for strength with more carbon and maybe some Kevlar.

[rod185651]

Mate, all trial, and error eh, if it was easy everyone would be doing it.

[JimZXR]

Cheers rod

[GammaBoy]

Just to be clear with everyone I've had a slight change of heart:

After watching the YouTube videos posted a few pages back and discussing the job with a work colleague who makes boats in his spare time I've decided to not make the mould from this unit and make a truly one-off seat unit instead by laying the carbon over my plug then after it's cured remove the plug from the inside by melting it with acetone.

As far as making another seat unit I'll be making an attempt using the HD Foam (as advised by Gix) once I have gotten over this current seat unit debacle!

My work colleague is confident I'll be able to make the seat unit work with just two layers of carbon on the outside then building it up inside for strength with more carbon and maybe some Kevlar.
Spray foam doesn't dissolve very well with acetone - you may find yourself digging it out bit by bit.

[JimZXR]

Thanks for the info mate; I'll have at it with a few strokes of the chisel!

[JimZXR]

Have been told only 3 more working days until I get my carbon cloth and resin!

[JimZXR]

Picked up the Smog block bars today so just have to fit them this weekend and see if they improve anything; doubt they will buy worth a try.

[JimZXR]

Carbon arrived today; count down to a full custom carbon tail unit!

[JimZXR]

Seems like I’m getting my new clutch kit next week too so seems like I’ll be having a quick flurry of activity to get the bike rideable soon!

[JimZXR]

Smog block off bars installed last night without a hitch which has got me a bit off guard as I expected more of a fight; even undid everything to make sure I had it all in right but all seems well.

Tonight's plan is to start the final shaping of the tail unit before applying carbon and copious resin over the top!

[JimZXR]

Sanded the plug down to where I’m happy then after a quick wipe down I applied a coat of resin to give me a good flat surface to wax once it’s sanded back a little.

Thinking of putting down 3 layers of wax before I attempt to lay the resin and carbon as it says in the videos Gix provided a few pages back.

Bricking it to be honest chaps as I’m in virgin territory for myself but I’m also a tad excited to get into it so wish me luck; this could be a very bumpy finish!

[JimZXR]

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[LKC73]

Looking great Jim, Should come out ok mate.

[Gix11]

The better the mold, the better the final piece. Try and get it the best you can and it'll pay off. Good effort mate.

[JimZXR]

Unfortunately Gix I’ve buckled and am making it a full one off my going over the top and remove ng the plug from within!

[JimZXR]

5 layers of wax applied and I'm thinking of laying down the Gelcoat tonight and hoping to maybe lay some carbon tomorrow

[GammaBoy]

So the Gelcoat is going to be on the inside of the part? If so, why bother with the gelcoat?
I could understand the gelcoat if you were making a mould from the part, but you're talking about using carbon, which makes no sense for the mould...

[JimZXR]

Yeah, found that out today too Gamma.

I was thinking the gelcoat would help it release but I’m told, as you have too, it won’t make any difference really.

[JimZXR]

Carbon applied; just waiting for it to cure overnight then can lay up some more layers on the underside after I get it off the plug!

[LKC73]

Carbon applied; just waiting for it to cure overnight then can lay up some more layers on the underside after I get it off the plug!
This will be exciting mate, sorry I wasn't around to over the weekend. Hope its working out well for you.

[JimZXR]

Checked it this morning and it’s far from a factory finish but considering it’s my first attempt I’m pretty happy so having it looked at by a mate at work to see how best to finish it so I’m thinking I may get to remove the plug this week then lay more carbon inside before I have a finished article by Christmas.

May even not paint it and leave it bare carbon for a while?!?

[JimZXR]

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[JimZXR]

Started removing the plug today and trimming back the overhanging carbon and have to say the foam doesn't want to come out easy, the filler even less and the carbon has shredded my hands but I'm getting there and still hoping for a 2017 run out but thinking it could be unlikely now!

In the very up side I've received my new clutch and will be fitting that soon with a new slipper release spring.

[JimZXR]

SUCCESS!!!!!!!!!

Got the tail removed from the subframe, cut the light hole and started to refit it.

All being well I'll get the tail and subframe into the bike tomorrow and be able to ride it come Friday!

Also FYI; Carbon bites REAL fucking hard!

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[ozzy1100]

That looks cool as fuck

[Azrael]

That looks cool as fuck

I agree and i dont normally like carbon

[rod185651]

Very Cool, how much lighter is it?

[JimZXR]

It feels crazy light to be honest mate and will probably weigh less again once all of the foam, plastic and body filler is removed but I'll also be putting down some more layers of carbon once the inside is clean so may double is weight from fuck-all to double-fuck-all!

Fitting the subframe tonight then will attempt to get the tail back onto the bike which will be a mission I'm guessing but once I'm more suitably gloved up (less hand shredding) I should be fine. Got to cut the hole for the fuel tap too but that shouldn't take long.

Also have the clutch cover gasket so will be swapping the clutch out and may yet also do an oil and filter change too for good measure!

Will throw up more photos tonight when it's hopefully "finished".

[LKC73]

That looks mad Jim. You should be proud mate coz you now have a one off tail! Great work bud.

[rod185651]

Mate, I salute you! you persevered and the end result is awesome.