'76 KZ900 (ZRX1200R) Build

NakedFun wrote: So Saturday was a lesson in 10 lbs of crap in a 5 lbs bag.... First off, I decided to create my dual remote mount.

The levers were a PITA to weld. I don't have access to TIG, so I have to MIG the 3/4" x .125" lever to a 1/2" - 16ga DOM tubing. They were so small, that I had to clamp the grounding clamp in the vise and then use the grounding clamp to hold the lever for welding. The welds look ugly, but have great penetration which is what I was looking for especially since my front brakes and clutch will depend on it..... I'll clean them up, but forgive my weld appearance this time around.... The pivots work great and smooth with the bronze bushings.

So now it is time to figure out where it would fit.... With the coils in place, it had to go directly behind them. This worked, however I then noticed there would be no way to pull the valve cover with it in that position, so you would have to remove it to do valve shimming. So it ends up the final resting place is under the seat, above the battery box.

The cables I will order will just follow the back bone of the bike and connect under the seat. The one down side is the custom HEL brake lines I ordered from Dave. The one now has to be ordered in a 20" longer custom length or put a junction under the tank and run a second line to the master. Thoughts? Extend the line or order new custom length?

Cory

NakedFun wrote: So I have a question to pose to the machining/engineering/thinkin' portion of the board. It comes down to bolted joint design. I am thinking about my securing method of the brake rotors and my cush drive basket to the wheel hubs. My original design requires the use of Flat Head Allen cap screws utiling an 82 degree counter sunk recess in the cush drive basket and brake rotor mounting holes. This would allow flush or very low profile securing for clearance and let me work with the 5/16"-18 fastener bosses on the hubs.

Now engienering practive teaches that button heads and countersunk/flat head Allen fasteners are not to be used in critical joint applications. However, ASTM F835 which specifically addresses this fastener type in its mechanical properties specifcally calls out for use in shear type applications is its designed purpose. Specifically fasteners of this type will have the properties of 145,000 psi Min Tensile and a C39 Min Rockwell specifications for diameters of 1/2" or less. There is no Min Yield or Min Proof for this type of fastener, most likely to the the head design....though i have not found the ACTUAL reason for this.

Does this seem feasible to use them for mounting of my brake rotors and cush drive basket to the wheel hubs? I have clearance issues that I need to deal with. I don't want to cause an unsafe situation. My only other option is to redrill the front hub using a jig and re-use the stock ZRX brake hardware.

Thoughts? Am I nuts?

Cory

531blackbanshee wrote: saweet gauges where did you get them?

leon