My long termer Z650

I reckon a Rg500 calliper hanger is what you want, 210mm, should fit the sv calliper..

Si - it's about as much of a roll as I ever manage... ;-)
Gammaboy - thanks for the heads-up, I've had a look at a couple of RG hangers, and while they look like they could be made to work they have got a steel and rubber sleeve for the spindle, which could be an issue. I might just get one to see whjat bore the hole is if the sleeve is pressed out...
Meanwhile, the cheapo Aldi-bought Dremel copy got some action...
http://i1078.photobucket.com/albums/.../IMAG02841.jpg although this does mean that I'll now have to check out the welds on the inside of the up-pipe joining headers to turbo as well now. The amount of difference it'll make, performance wise, is totally negligible, but it makes me happy doing it...

no one would know its there other than you......and that is why it must go lol

Hey mate, measured one up that I've got here, didn't even notice the rubber bush! Anyway, 32mm if you press the rubber out, I'd just press it and knock up a top hat spacer to suit if it was me...

As it happens, as I was lying awake at about 2am this morning, I realised that pressing out the rubber bushing and using a top hat spacer would not only suit the 25mm spindle but meant that I could get the spacing sorted without extra loose spacers... Game on! Thanks GB!

I pulled out the standard battery box to see how much room I was going to have to fit a new (larger) battery.
http://i1078.photobucket.com/albums/.../IMAG02711.jpg
http://i1078.photobucket.com/albums/.../IMAG02721.jpg
And then went for a wander around t'interweb to see what kind of battery would suit my needs. I wanted a bigger battery as the standard acid battery (as per the original Z650) wasn't really man enough for the 1100 engine when I ran it before, it'd kick back on the starter, so I wanted something that not only had the potential to spin the starter a bit faster, for a bit longer, but also one that would have no issues with continually running the oil pump I'm going to use to lubricate the turbo. And that oil pump was (temporarily) mounted here...
http://i1078.photobucket.com/albums/.../IMAG02791.jpg
http://i1078.photobucket.com/albums/.../IMAG02811.jpg
http://i1078.photobucket.com/albums/.../IMAG02801.jpg
Although I'm starting to think twice about it sitting there, given that I have to fit the oil tank somewhere as well, in a place that the turbo oil can drain into it efficiently...

Shit; you should be able to find a good modern battery that will punch out a kick that will fit in that cavern easily!

This is what I connect my gonads up to. Groovy name too :)

http://shop.antigravitybatteries.com...g1201/#reviews

Hint to fix the kick back, wire the starter so that you can spin it with the kill switch off - hit starter so it's spinning, once spinning hit kill so it has spark...

GB - was actually planning on doing the wiring so it could be span over with no spark, as I like the idea of checking for oil pressure before it fires and goes straight up to 2k rpm...

I'd had a look at various battery sizes on line and, having chosen one with a nice fat output, decided to mock up a cardboard version to see if it's fit. Although it didn't go according to plan at the first attempt...
http://i1078.photobucket.com/albums/.../IMAG02751.jpg
Fortunately, the second one was a bit better, so I could see how well it would fit, firstly longitudinally...
http://i1078.photobucket.com/albums/.../IMAG02781.jpg
Which, quite clearly, wasn't going to work, so I tried it crossways...
http://i1078.photobucket.com/albums/.../IMAG02771.jpg
Which is better, but it's clear that it could only go so far forward between the frame rails, and that the plastic mudguard (one of the few original Z650 parts) would have to be altered.
http://i1078.photobucket.com/albums/.../IMAG02761.jpg

I do like the first attempt, reminds me of a few of mine.

I managed to get a second-hand Dyna 2000 (from a helpful chap on the Z1 Owners Club forum), so that's been stashed somewhere safe while I carry on with the battery box.
The battery turned out to actually be pretty close to the cardboard dummy that made, which was surely luck and/or coincidence more than my accuracy with cardboard. As that first effort kind of shows... Ahem.
http://i1078.photobucket.com/albums/.../IMAG03071.jpg
So after some judicious measuring of the frame area and the original steel battery box, I chopped up some more cardboard and made a faux battery box before I started cutting aluminium. as the new battery is wider (and taller) than the original, it's going to have to sit further back in the frame so, as I want to use the standard battery box mounting points, there was going to have to be a certain amount of offset in the box. which is why the cardboard one is too big from front to rear.
http://i1078.photobucket.com/albums/.../IMAG03261.jpg
And sliding the carboard battery box between the frame rails shows that some of the plastic rear mudguard / undertray thingy is going to have to be cut out to allow it to fit.
http://i1078.photobucket.com/albums/.../IMAG03271.jpg
Now to go and cut some 3mm aluminium...

Got plenty of clearance in front of the rear wheel for the box to protrude?

Yes Si, plenty of room. The Martek swinging arm is slightly longer than standard and, even with the wheel as far forward as it can go there's loads of clearance. The pic is probably a bit deceiving, I'll post another later that shows how much room there actually is.

Ally cut to size / shape and put in the el cheapo folder thaat I had stashed under the bench...
http://i1078.photobucket.com/albums/.../IMAG03281.jpg
And tried for size in the frame. Quite clear that the rear mudguard needs to be relieved...
http://i1078.photobucket.com/albums/.../IMAG03291.jpg
So it was marked up thus
http://i1078.photobucket.com/albums/.../IMAG03301.jpg
And with the help of Charlie Dog, my faithful workshop companion...
http://i1078.photobucket.com/albums/.../IMAG03341.jpg
... had a chuffin great hole hacked in it, using my Dremel-a-like and rotary saw blade.
http://i1078.photobucket.com/albums/.../IMAG03351.jpg
Although the saw did take a liking to a finger too. It's tasted blood now...
http://i1078.photobucket.com/albums/.../IMAG03371.jpg
And a trial fit showed that a bit more had to come out.
http://i1078.photobucket.com/albums/.../IMAG03361.jpg

now you know your having fun when blood comes out , looking good so far , I have one of the moto batts in the vfr well over 3 years old and still going strong

I tacked a couple of pieces of ally plate to the front and back of the bent piece, with the back being bigger so as to hopefully cover the battery from any crap thrown up by the back wheel and going through the new hole in the undertray thingy... I'll add another piece at some point to hold the battery in place, although as it's going to be close to the underside of the seat, it'll not being going anywhere. I hope.
http://i1078.photobucket.com/albums/.../IMAG03591.jpg
And then I welded up the joins. It's not very pretty, but better than my last attempts with the TIG. I'm using a foot pedal now, and I think that's helping.
http://i1078.photobucket.com/albums/.../IMAG03621.jpg

Shed built cool; good work mate.

Cut cut grind grind.... I thought the red stuff is surposed to
stay on the inside....
As for ally tig, y is it I can weld everything
beautiful and yet struggle with fucking ally lol feeling yr pain

Ozzy - my ally welding is better than my MIG welding, which kind of tells you just how crap I am with a MIG...
So, battery box welded up with brackets added to hold the Mosfet all-singing regulator/rectifier, and the Dyna 200 unit (which will be held on with rubber straps / o-rings against a vibe-absorbing rubber pad), and ready to be slid into the frame once more...
http://i1078.photobucket.com/albums/.../IMAG03661.jpg
Buggeration. I'd measured up for the brakcet for the reg/rec, locating it neatly behind the right hand side panel. Completely forgetting that if I made the battery box any wider it'd not fit between the frame rails.
http://i1078.photobucket.com/albums/.../IMAG03651.jpg
What a prize prick! Hey-ho, back to the grinder again to chop off the offending bracket. The reg/rec will have to be located somewhere else, probably hanging below the battery box yet still on the right hand side.