Project Procrastinate

[MDM]

Some of you may remember that, way back in the mists of time, I started off a project that was, essentially, a bike build out of the bits that I had scattered around the Shed of Dread.
Given that it was a Streetfighters magazine project build, there was no real surprise when progress was very very slow. And then the mag folded...
At that point, the Z750 frame had been fitted with a GSX-R750 motor, and ZX-6R front end and a GSX-R 1000K4 swinging arm and rear wheel, and some Kawasaki bodywork sourced to match the 750 tank.
It was then stashed under a sheet and forgotten about for knocking on close to 5 years...

[MDM]

After two house moves, with the project still in the Shed of Dread, I had organised a new garage with enough space, so it was collected in the Hotel Berlingo8525.

[MDM]

And, several months after that, it peeks out from under another, different cover.
8526

[MDM]

To look like this:-
8527

[Gix11]

So is the ball going to start rolling again mate?

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[MDM]

Yep, the ball is rolling...

[Gix11]

Happy Days

[MDM]

There had been a bit of delay while focus was directed elsewhere.
I stripped and rebuilt my SV650, hoping that I'd be able to use it as a track bike this year (this was before Covid-19 reared is ugly pointy head), with a new subframe, Fireblade tail unit, Hornet nosecone, forward mount battery box, bellypan, new fork internals, and a set of fuel injection model cams.8535

[MDM]

Oh, and I'd got hold of a pitbike suoermoto too, for some cheap trackdays on kart tracks, but again I was thwarted by virus reduction procedures...
I'd stripped this and replaced fasteners and bearings, fitted new bodywork, new wheels, decent Mikuni carb etc... although I don;t seem to have a pic handy right now.

[Gix11]

Lots of track talk. Have you moved somewhere close to a few tracks by any chance?

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[MDM]

By Aussie standards, every track in the UK is 'close'... :D but yeah, Cadwell Park is about 14 miles up the road... and there's a kart track that was doing bike days about 14 miles in the other direction, but they've stopped bikes now due to noise complaints :mad:

[Gix11]

Cadwell down the road! Awesome.

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[MDM]

8536
Stuff has started. Although initially most of that 'stuff' has been working out what I need to get to continue the project, and then searching for it on the interwebs.

[MDM]

Not much room above the carbs, but even if it's only 1 mill', it's still clearance.8537

[MDM]

8538The rear shock linkages had left the rear end a little low, even with the adjustable top shock mount wound in to its highest point. So I made up some new tie bars, so the shock mount is now around about the middle of its adjustment.

[MDM]

I had a Ducati rear brake master cylinder in a cupboard -as you do - and wanted to use it as it's a little different and cold make for a neat install...
8539

[MDM]

Although the backing plate needed some tweakage to sit parallel to the lower frame rail.
8541
Astoundingly, I got it parallel using just a file.
8540

[Gix11]

This is great! Keep it coming....

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[ozzy1100]

This is great! Keep it coming....

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Sorry dude I still have no access to pictures [emoji25]


More human than human

[Gix11]

Sorry dude I still have no access to pictures [emoji25]


More human than human

Do you mean you can't see any pictures on the forum at all mate?

[ozzy1100]

Do you mean you can't see any pictures on the forum at all mate?

No just in members mate, the paypal thing still [emoji2357]


More human than human

[ozzy1100]

What ever you did fixed it good sir [emoji106]


More human than human

[MDM]

As it stands, I've got a set of sidepanels from a Z1100 (I think, might be the Eddie Lawson rep), and a modifed tail unit that was created from an ELR tail piece, a sheet of steel and a shit load of fibreglass and body filler, and it weighs a LOT. It was only mocked up to get the short & stubby tail unit that I wanted, and I had originally intended for a blag to get it copied in fibreglass (at that point it was a mag project, and blagging was on the cards).
As it is now, I'm going to have a go at making some moulds and replicating the tail unit and sidepanels myself. I could fit the sidepanels as they are, but would like to have some of the ides extended to meet the frame rails, and I want them fastened with proper fasteners, and not the standard 'pop in and hope' nipples and rubbers...
8542854385448545

[Gix11]

Ahh yes, good old fibreglassing. The job you forget how much you hate until you have it all over your hands and forehead.

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[Gix11]

....good luck by the way.

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[MDM]

Thanks Si. I'm both looking forward to it, and dreading it at the same time...
Will start with one of the sidepanels and see how it goes - the tail unit it going to need a three piece mould, so will be a proper headfuck. Start simple...
I've given the panels a treat with several grades of wet and dry, now it's on to the polishing.
85468547

[ozzy1100]

Thanks Si. I'm both looking forward to it, and dreading it at the same time...
Will start with one of the sidepanels and see how it goes - the tail unit it going to need a three piece mould, so will be a proper headfuck. Start simple...
I've given the panels a treat with several grades of wet and dry, now it's on to the polishing.
85468547

Beautiful markings on kitty dude [emoji106]


More human than human

[MDM]

That's Buster the Magnificent - survivor of an atrocious road accident, and currently clerk of the works in the Garage of Shattered Dreams...

[ozzy1100]

That's Buster the Magnificent - survivor of an atrocious road accident, and currently clerk of the works in the Garage of Shattered Dreams...

Shed/stable cats are the best people ever.... well more personality than people that for sure [emoji106]


More human than human

[MDM]

In a bid to distract myself from the woes of the Zed build, here's some of the things left to do on this one... more to be added as and when.8844

[Gix11]

Looks like the menu at our local Chinky before it closed.

Not much to do then.....?
Let's face it, you'd be looking for another project if the list was smaller.

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[MDM]

Another project you say?... Hmmm, tempted...

In the meantime, spacers and stuff arrived from a mate.
Spacers fitted to lower rear engine mount, and bolt shortened and re-threaded to suit. Bungs tapp8846ed for 8mm and slid into rear framerails, will be used to support a subframe / undertray thingy at a later date...8845

[MDM]

Also pondering cooler choice - which ones, and where...8847

[ozzy1100]

Also pondering cooler choice - which ones, and where...8847

Dude that can turn into 3 mths of work before you know it [emoji23]


More human than human

[MDM]

Fibreglassing continues. Much of it going in hair / clothes / loc885088518852kdown beard...

[Gix11]

Hang in there mate!

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[MDM]

More layers on the first part of the tail mould...
8853
And then the sign board divider was removed to start on the second part. The plasticene filler was trimmed up, and removed from the locating 'bumps' before more beeswax polishing and then gel coat...
8854

[MDM]

Moulds completed...885688578858

[MDM]

And then, with a little persuasion, split apart.
88598860

[MDM]

And I have a three piece tail unit mould!
8861

[MDM]

And two side panel ones too...
88628863

[Gix11]

Gotta be happy with that!

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[ozzy1100]

Dude that is fucking outstanding thumbs up


More human than human

[MDM]

I'll not get cocky until the final piece is out of the mould... but fingers crossed it's going okay so far...

[ozzy1100]

Yes but in my experience the mound is what kills your will to live the most lol


More human than human

[MDM]

Tail unit persuaded out of the mould, with a little damage to the gel coat, and a little flimsy in a couple of places, but that's easily rectified...
8866
88678868

[Gix11]

Hell yea! Result.

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[ozzy1100]

That is fucking awesome [emoji106]


More human than human

[MDM]

Thanks gents ;)
And you might have noticed from one of those pics that I've been thinking about using an oil cooler from a Diavel...
8869

[Gix11]

That fits thete pretty well hey? How would the actual cooling go though considering you would have a side cover and your leg covering it? Not a lot of airflow, or would it be fine?

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[ozzy1100]

That looks like it was meant to be there


More human than human

[MDM]

That fits thete pretty well hey? How would the actual cooling go though considering you would have a side cover and your leg covering it? Not a lot of airflow, or would it be fine?
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If it does end up there, and it does kinda fit nice, then the side panel will have either vents, or holes or summat, to allow it to 'breathe', and I've got an R6 radiator fan that is small,and could be used to push or pull air through the cooler...

[Gix11]

Now that sounds like the right answer! Sweet.

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[ozzy1100]

If it does end up there, and it does kinda fit nice, then the side panel will have either cents, or holes or summat, to allow it to 'breathe', and I've got an R6 radiator fan that is small,and could be used to push or pull air through the cooler...

Another awesome solution


More human than human

[Fish]

Very nice work. I'm procrastinating on fibreglassing work myself.

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[ozzy1100]

Very nice work. I'm procrastinating on fibreglassing work myself.

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Don’t do it stay away from the light lol


More human than human

[MDM]

Get stuck in Fish. I procrastinated for far too long, but once I got doing it, it was actually a bit of fun. Rather satisfying...

[MDM]

I finally managed to get the sidepanels out of their moulds, aided by trimming down the excess fibreglass hanging out side of the mould, easing a Stanley blade between the mould and final part, and blowing in some air from the compressor.8870

[ozzy1100]

I finally managed to get the sidepanels out of their moulds, aided by trimming down the excess fibreglass hanging out side of the mould, easing a Stanley blade between the mould and final part, and blowing in some air from the compressor.8870

They look like they came out great dude [emoji106]


More human than human

[MDM]

Meanwhile, I made some oil cooler brackets an ting...
8871

And was wondering about headlight brackets / fork clamps, but didn't want to splash the cash for billet CNC machined jobbies, or settle for the cheapo (and nasty) aftermarket crap available. So I bought a bottom yoke from some kind of Suzi 'crosser.
8872

[MDM]

And introduced the yoke to Messrs Chopsaw, Grinder and File.
8873887488758876

[MDM]

Made a couple of extra brackets, got a mate to add some blue glue, and here we have an answe88778878r to a different question than "What headlight brackets can I use?"...

[ozzy1100]

I like that solution [emoji106]


More human than human

[MDM]

I had originally thought that the battery would go behind one of the side panels, but 887988808881I found an old battery box and started trying it for size.
After some fiddling and thinking with a cup of tea in hand, I cut a bracket from L section aluminium, bolted the battery box to it and then it all to the ally slugs in the frame rails and took a look.
Happy with that, I got it welded up by a grown up, with a couple of strengthening tabs, and bolted it back on...

[Gix11]

Mate, you're on fire with the build at the moment! This is going to be seriously cool when you're done. Keep it coming.