Drill tap add later...
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Drill tap add later...
I added a piece to the base, so the reg/rec is still at the right-hand side, at the bottom of the sidepanel, so should get some airflow too.
http://i1078.photobucket.com/albums/.../IMAG03681.jpg
And the battery box now slides into place, and it sits in position like this...
http://i1078.photobucket.com/albums/.../IMAG03701.jpg
... with the reg/rec in place.
And from the other side, with the Dyna 2000 held in place temporarily with some tie wraps. It'll be either o-rings of rubber bands cut from inner tubes that hold it when finished.
http://i1078.photobucket.com/albums/.../IMAG03711.jpg
There you go! All sorted. Nice one.
I'd leave the zip ties :-)
With an aftermarket oil cooler set to replace the standard one, I had a root through my cooler stash in the cupboard, and set to making up some brackets.
http://i1078.photobucket.com/albums/.../IMAG03061.jpg
I'm going to mount the oil cooler off the two reflector mounts on the front frame down tubes, using rubber mounts like these bobbins, which were a nightmare to find, and chuffin' expensive too. Anyone know where they can be found cheap?
http://i1078.photobucket.com/albums/.../IMAG03161.jpg
As you can see from the above pic, I'd got some stainless steel tube to make the spacers, it just needed cutting down...
http://i1078.photobucket.com/albums/.../IMAG03171.jpg
And I made up a couple of 'ears' to hold the rubber mounts, that would need to be welded onto the cooler bracket.
http://i1078.photobucket.com/albums/.../IMAG03181.jpg
Like this -
http://i1078.photobucket.com/albums/.../IMAG03641.jpg
And then the bracket could have a bit taken out of the middle to make it look nicer...
http://i1078.photobucket.com/albums/.../IMAG03671.jpg
And tried in place to see if it fitted okay...
http://i1078.photobucket.com/albums/.../IMAG03691.jpg
Seems okay, wonder what it looks like with the cooler added?
http://i1078.photobucket.com/albums/.../IMAG03721.jpg
Hmmm, might take a bit more off the upper mount to be able to run the oil lines a bit neater, but I think it's getting there?
are you also going to make lower mounts for the oil cooler mate? btw neat design, made me re think my own variants, i had 2 options, 1 is fix the oil cooler to the frame with U mounts which is simplier but uglier than option ii - welding ears straight to the i.c.'s lower tank. so im choosing var ii. maybe i'll also fab a V shaped lower mount from an ally or stainless steel rod, smth like 8mm od. i mean the top of the V would be fixed to the center of the lower panel of the oil cooler and the rays of the bloody V rod (lol) would be fixed to the engine's upper mounts, hopefully you get what i mean otherwise you will be able to see it in a while...
im talkin about my b12 this time fuck all those bikes haha!
ps have a lot of those rubber bushings of different types, some of oem intercoolers and oil coolers mutulated by me, some of side panel mounts etc, would throw em to you but itd be a mighty big throw
I like that
Surt - nah, just hanging off the two top mounts, like the standard GPz cooler. Although will probably add a rubber 'bumper' to the frame down tube for the bottom of the cooler to rest against, a bit like the cooler on a Bandit.;)
got it, i'll see if i have to add lower mount when i finish the upper ones. usually i judge by eye and feel lol
Very tidy. How's the gap between the headers and cooler? Another deceptive photo?
Yes Si, another deceptive pic... it's close, but there is clearance. I wanted to have the cooler as low as I could so that it wouldn't interfere (as much) with the steering lock. ;)
So, a mere ten months later, ahem.
This is just a bit of advance warning - I wouldn't want you getting all shocked and hyperventilating - but I've done some more stuff on the Zed. Pics uploading right now...
Sweeeeeeeeet.......
Uploading where?? You tease.
Haha, onto Botophucket...
Although as I've been doing various jobs on various parts - exhaust, inlet manifold, engine breather tank, rear light mount etc - nothing has actually been properly finished, so this is going to end up looking really random unless I group the pics together when each part is completed...
And no, that's not an excuse. Honest.
I finished one thing though. A retaining strap for the battery.
http://i1078.photobucket.com/albums/...231_125644.jpg
Although, now I think about it, that's not finished as I may add a rubber 'bumper' into the middle of it, just to hold the battery a tad more securely...
I fettled the battery box a bit as well, and it now slides into position a bit more easily, and has a nicer profile.
And that big white thing at the bottom of the pic is a horn that I'm using - originally intended for boat use. It's quite loud...
Boat horn; now that should cause some looks. Yea, I'd be adding more rubber than you think to that battery box as well. I did everything hard mounted when I first made the big changes and have slowly had to replace everything over the years. Even the old GXSR standard box has a hard felt like liner around the top to stop the battery moving or vibrating too much.
More photos vicar....
boat horn sounds awesome, you just need a nice foggy day !!
I'd made a stainless steel flange (fnarr) for the Rajay turbo outlet ages ago, so it was high time that I did something with it.
With a 90 degree stainless bend, with one leg shortened, it was squeezed into the flange like so.
http://i1078.photobucket.com/albums/...03_1932101.jpg
And you can see some cut-down stainless bends on the bench as well, which got tacked together...
http://i1078.photobucket.com/albums/...227_141527.jpg
And then bolted back on to see if they looked something like...
http://i1078.photobucket.com/albums/...227_143153.jpg
I'm going to slash cut the exit, although I'm still not 100% sure about it. I'm going to make another, baffled, pipe that runs to the rear of the bike that I can use when the bike is MoT tested and also if I ever decide to take it on track (either at a noise-limited run-what-ya-brung, or a track day might be fun...)
My limited knowledge of turbos now has me wondering how the outlet facing forward is going to handle being rammed with air? Or is this another of those "deceiving photos" episodes? Edumacate me...
Regardless of that; I love any kind of stainless tube work, looks great!
not just ram it, but also the jet would slow down the movement being directed forward
but it does look great
blah...... I doubt it anyone could ever tell the difference...
lol i just was trying to be a smart arse mate
Same you crazy rusky fucker lol
Yeah, a slightly deceptive photo - the pipe does point forward-ish. But it's going to be slashcut so the exhaust will be directed outwards rather than forwards although, as Ozzy1100 said, it'll be next to no difference anyway. There are loads of draw-though set-ups that have the dump pipe routed forward over the up-pipe, and they all run okay, so I have no worries there.
Besides, it was the only place I could have it running - I didn't want it pointing directly at the ground, I didn't want it pointing back at my foot, and I didn't want a high level pipe running back to the rear shock mount (although I am making a second pipe that is just like that, albeit with a baffle for MoT porpoises). :-)
I asked a grown-up to stick the bits together properly.
http://i1078.photobucket.com/albums/...08_1355501.jpg
Yep, that's an ASF hoodie.
Shed of doom?
Excellent all round.
So, ages ago I mentioned that the carb wouldn't fit in a manner that would allow it to work very well...
http://i1078.photobucket.com/albums/...t/IMAG0034.jpg
Usually the carb slips into this flange that bolts onto the turbo body
http://i1078.photobucket.com/albums/.../IMAG03791.jpg
So I needed to find a way of offsetting that flange forwards and outwards...
I got a cast aluminium bend, and marked it up where I guesstimated would work...
http://i1078.photobucket.com/albums/...228_160646.jpg
And cut it. The piece of paper is a template for the flanges to go on each end of the pipe to A) bolt to the turbo and B) hold the flange for the carb
http://i1078.photobucket.com/albums/...230_154115.jpg
And if it was wrong I still had the other piece of bend
At which point I went over to FBM for the final welding of the dump pipe, whereby he produced a pair of ready made flanges that he welded to the bend! So much for fannying around making my own flanges...
http://i1078.photobucket.com/albums/...109_113410.jpg
It needed some material trimming off, but it was looking close...
And bolted to the turbo...
http://i1078.photobucket.com/albums/...109_115722.jpg
Tadaa! The carb flange mounted (with holes redrilled and tapped to take 5mm allen head bolts) and the carb slipped into place.
http://i1078.photobucket.com/albums/...109_152309.jpg
Note, however, that the tank actually has to come down a bit yet as it's being held falsely high by the rose-jointed brace that steadies the turbo, and that fuel tap is perilously close to the carb... We're not finished here.
Shit mate, this is more progress than the last 12 years! You're on a roll!
Yeah! And not only that, but I get to say the word 'flange' a lot! :-)
Meanwhile, things were happening. Only little things, but at least something was being done. Small steps, but all in the right direction. Mostly.
The swinging arm shock mounts on the Martek arm were further apart (across the bike) than the standard Z650 mounts, but then you'd expect that when upgrading to a 180 section tyre I guess. I had originally been happy with the Maxton shocks sitting angled inwards from the new mounts to the standard upper ones, but over the last few years I'd grown less happy with them, so wanted the upper mounts moving outwards to match.
http://i1078.photobucket.com/albums/...103_121729.jpg
I found that a bloke on the Z1 Owners club forum was making adaptors that extended the shock mounts outwards, and somewhat conveniently they happened to be exactly the right dimensions to suit the shock mounts on the Martek arm. Yippee!
http://i1078.photobucket.com/albums/...103_122144.jpg
http://i1078.photobucket.com/albums/...103_123613.jpg
They'll need to be welded onto the frame, but that can happen when I do the frame mods for the chain run (oh, did I not mention the chain run issues...)
I was never happy with the bolts in the lower shock mounts, as they had threads running through the mounts, so I got a couple of bolts with long 'shoulders' that I re-threaded so that the shoulders ran through the shock and mounts and the thread was only up to the inside face of the mount.
http://i1078.photobucket.com/albums/...109_111948.jpg
http://i1078.photobucket.com/albums/...109_142424.jpg
Much coolness :-))))
As I mentioned previously, I had a rose-jointed support to hold the weight of the Rajay hanging from the standard tank mount, but it was too chunmky and got in the way of the Tank Shop alloy tank...
http://i1078.photobucket.com/albums/.../IMAG02701.jpg
So I took it off and threw it into the 'might come in handy one day' pile.
Measuring up for a more svelte bracket, it was clear that it wouldn't just be a straight piece of steel that'd do the job.
http://i1078.photobucket.com/albums/...116_163748.jpg
I found a pice of angled steel and, with a bit of chopping, bending and welding, made a bracket that fitted something like.
http://i1078.photobucket.com/albums/...131_151700.jpg
Hopefully it'll help support the weight of the turbo and give a bit more life to header gaskets etc.
http://i1078.photobucket.com/albums/...131_151615.jpg