1977 KZ1000 Restomod

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20 Jun 2021 00:46 #850441 by calum
Replied by calum on topic 1977 KZ1000 Restomod
The cover is from a small business nearby: www.tmhg.de
They made a bunch a while back for the KZ1000 and I got the last one.

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  • DOHC
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  • Those Doe-Hawks really go!
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20 Jun 2021 19:54 - 20 Jun 2021 19:55 #850505 by DOHC
Replied by DOHC on topic 1977 KZ1000 Restomod

. Not sure about the clutch cover - may be a touch too "boy racer"...

It doesn't really look boy racer to me. But it does look a bit like a front loading clothes washing machine. :)

I wonder what it would look like with the engine running. Based on the amount of smoke and oil that come out of my ZRX when I open the cap in the clutch cover, I feel like you might see some things that you'd prefer stay hidden.

'78 Z1-R in blue , '78 Z1-R in black, '78 Z1-R in pieces
My dad's '74 Z1
'00 ZRX1100
Last edit: 20 Jun 2021 19:55 by DOHC.

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20 Jun 2021 21:15 - 20 Jun 2021 21:15 #850509 by calum
Replied by calum on topic 1977 KZ1000 Restomod

But it does look a bit like a front loading clothes washing machine. :)


 
Last edit: 20 Jun 2021 21:15 by calum.

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23 Jun 2021 14:14 - 24 Jun 2021 02:44 #850660 by calum
Replied by calum on topic 1977 KZ1000 Restomod
Picked up the head today. Had the following done:
- Bead blasted and pressure washed
- Cracks repaired (ground out and laser welded)
- Tach-drive welded up (it was broken off when I got the head and still needs some sanding/shaping but I'll do that myself)
- Resurfaced
- Porting (opened up the intake valve seats and opened up the intakes to match the carb boots)
- Valve seats cut (didn't want to get the Neway's out on this build)
- New valves (machined so all the shims are at mid-range)
- One valve guide needed replacing

One of the plug threads had a helicoil in it before. It got removed so the cracks could be fixed and then replaced with a new one. 









 




Here is one of the crack repairs. The area next to the weld is still black from the welding, would have thought it would be cleaned up when the thread was tapped again. There is no real noticeable edge between the weld and the original thread though, so I guess the old thread is just a tiny bit larger (maybe due to wear?):

Last edit: 24 Jun 2021 02:44 by calum.

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23 Jun 2021 14:22 #850661 by zed1015
Replied by zed1015 on topic 1977 KZ1000 Restomod
Make sure the bucket doesn't stick in the bore next to where the tach drive was welded.
It's common to get a bit of distortion that needs relieving when having weld repairs done near them.

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23 Jun 2021 14:26 - 23 Jun 2021 14:37 #850662 by calum
Replied by calum on topic 1977 KZ1000 Restomod
Here's some more pics from the guy who did the work.
Need to check with him before I start posting his pics... 
Last edit: 23 Jun 2021 14:37 by calum.

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23 Jun 2021 14:29 - 23 Jun 2021 14:30 #850663 by calum
Replied by calum on topic 1977 KZ1000 Restomod

Make sure the bucket doesn't stick in the bore next to where the tach drive was welded.
It's common to get a bit of distortion that needs relieving when having weld repairs done near them.
The guy checked everything when he was doing the valves and said everything ran smooth, but I will double check. It was laser welded though, so shouldn't have any problems with distortion.
Last edit: 23 Jun 2021 14:30 by calum.

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  • Scirocco
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23 Jun 2021 15:39 #850668 by Scirocco
Replied by Scirocco on topic 1977 KZ1000 Restomod
Laser welding didn´t create much heat. Here is a video about a crank and cam shaft bearing gallery repair.
He works presice like a dentist.

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11 Aug 2021 03:03 #853550 by calum
Replied by calum on topic 1977 KZ1000 Restomod
Getting back into things again...
Got the triple clamps back. Had 7.5mm taken off the bottom and another 7.5mm to countersink the nut - this is only 44mm in diameter otherwise it would have broken out the front of the clamps, meeans the stock nut doesn't fit. I made up a nut out of 6082 aluminium just to see if I could (had some round stock lying around and just got myself a small lathe). I'll either make another one out of 7075 or mill down the stock nut. The 6082 nut will be OK for setting up the geometry.
Made a holder for the cutter. Now just need to make a drill guide and I can get the holes for the shock mounts drilled. Will double-check the geomtry later today and post some numbers.











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11 Aug 2021 05:53 - 11 Aug 2021 05:57 #853561 by Rick H.
Replied by Rick H. on topic 1977 KZ1000 Restomod
Nice job especially for using such a small lathe!  What make lathe is that one?

Rick H.

Rick H.

1977 Kawasaki KZ-1000A1
Last edit: 11 Aug 2021 05:57 by Rick H..
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11 Aug 2021 13:07 #853597 by calum
Replied by calum on topic 1977 KZ1000 Restomod

Nice job especially for using such a small lathe!  What make lathe is that one?

Rick H.
Thanks Rick, I was pretty happy when the thread actually fit the steering stem :)
The lathe is a Proxxon PD250. Pretty small but big enough for most parts and sturdy enough to turn steel, as long as you have patience. I've only tried 16MnCr5 which supposed to be pretty good for turning (have no real clue about which alloys to use where - working on that...)
 

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  • DOHC
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11 Aug 2021 14:43 #853601 by DOHC
Replied by DOHC on topic 1977 KZ1000 Restomod

Got the triple clamps back. Had 7.5mm taken off the bottom and another 7.5mm to countersink the nut 
Countersinking the nut is a cool detail.  Is there any risk that the top clamp might touch the tank now that it's lower?

'78 Z1-R in blue , '78 Z1-R in black, '78 Z1-R in pieces
My dad's '74 Z1
'00 ZRX1100

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