My long termer Z650

[MDM]

I'd got the offset sprocket from Debben Performance, and chucked it on (with a straight edge held against it for chain clearance reference).

And after routing through my drawers (madam!), I found a part-used 530 chain that originally came with the GSX-R1000 swinging arm that I have for another project, so popped that on too.

You can see that it hits the frame... Bugger.
Here's where I'll need to be pocketing the inside of the frame rails.

And, while I was here, I made up a cardboard mock-up of the oil tank for the turbo (I'll be running a seperate electric oil pump to oil the turbo, given that the air-cooled Kawasakis don't have great oil pressure)

[Gix11]

That pocketing on the swingarm will only be very small judging by the photos, yea?

Oh, by the way; loving the progress mate!

[MDM]

Probably going to take up to 10mm off the inside of the frame rails Si...

[MDM]

With the cardboard mock-up of the oil tank knew that it'd fit okay at the front of the swinging arm, so set to to make the bits to make the tank, albeit with a tweak to the design to make it taper downwards.
Firstly marking out the sheet of alloy.

Bender!

This shape appeared -

[MDM]

Years (and years) ago I'd started making a breather tank from an old aluminium gas bottle that my mate had found at a scrapyard. I'd cut a slice off it and had it welded up, so that it'd fit under the tail unit.


The problem was, I hadn't considered tyre clearance on the underside...

So I did some chopping and cut a section out.

Then made some pieces to fill it in.

[Gix11]

Mmmm, snug! This is great mate, don't stop now.

[ozzy1100]

Probably going to take up to 10mm off the inside of the frame rails Si...

You slicing or hot bashing? I'd say slicing lol
The frame jig I'm making will give me the option of spreading
the frame rails, automagic in Japan have some really cool ideas
on the subject. I'm very much looking forward to visiting them this may



Love what your upto much fun

[MDM]

Yes Ozzy, cutting then plating.
If I was doing it totally from scratch (ie with a different swinging arm) I'd put a new, bigger swinging arm pivot in. But I'm not... :-)

[MDM]

I'd bought a filler cap and tube of the interwebs, and made up a pair of brackets to use for rubber-mounted hangers for the oil tank, and took all the bits over to my good friend at Fast By Me turbos to glue them together, like so...

[Gix11]

Yes and yes!

[ozzy1100]

Dave is the man

[K6Thou]

Liking this Dave.

[MDM]

Thanks fellas!
Another little job that I'd be procrastinating over (what, me? Surely not...) was getting the mounts sorted for the horn.

The horn (bought from a canal boat chandlers) had one mounting point already on the original electrics plate, but needed to lower mount adding. So I cut out a piece of steel sheet to fill in the gap on the plate -

And then a passing pigeon pooped on it to hold it into place...

The object at the bottom of the pic of the bracket I made up to hold the electric oil pump - a piece of stainless tube welded to a plate with a couple of supporting pieces. I was a tad happier with the welds on this bracket than those for the horn piece...

[Gix11]

Yea, but it's just a horn mount! Who cares if it has pretty welds? More beer will make them better.

[geesexar]

lovin this thread Dave..keep up the awesome work

[MDM]

While I had the MIG out, I made up a pair of brackets for the oil tank to weld onto the frame cross member where the centre stand was once mounted, and tacked them in place. they can be properly welded up when the whole thing is stripped down.




With the bracket made for the oil pump, I planned for it to be rubber mounted to a matching bracket on the frame, so I cut out some sheet steel and blobbed it together. It ain't pretty in this pic, before it was tidied up.

Knowing roughly where I wanted it (on the removable cross-member come rear engine mount), I unbolted it and wiggled it out (a tad awkward with the engine still in place), cleaned the powder-coat off and welded the bracket into place. Fully. Not tack welds.


Guess what? Yep, it's in the wrong place. It needs to be further over to the left to give room for the feed and return lines.
So, back out it comes, cut it off with a slit saw, clean it all up again and re-weld, this time only tacking it in place to make sure it was right. Lesson learned. The oil line can now run up from the oil tank at the right hand side to the pump, then from pump to turbo and then the big oil return hose can go back to the tank at the back of the engine, towards the chain side.

[Gix11]

Coming together!
One little thing though with this photo:



Is the rear wheel off the ground or is the suspension loaded? Just thinking it might get smakced the first time you get airborne or the weight is removed in another fashion.

[MDM]

That pic is with the suspension totally unloaded Si (note the axle stands under the frame rails), so there should be plenty of clearance for airborne shenanigans / bridge jumping / stoppies etc...

[ozzy1100]

love this build

[Gix11]

What a dick. I completely missed the axle stands and they're hardly hidden! Obvious now you say it, and I mean, why wouldn't you have thought of that anyway? My brain was trying to see around the right of the photo to see if the tyre was on the hoist platform. I'll get back in my cage.