1977 KZ1000 Restomod

Looking really good, Germany is one of the toughest countries to modify vehicles and still be legal

Thanks. And yeah, they definitely make it hard to do any real mods over here. It was hard enough just getting the 750 legal and that was almost all original - most of the problems came from it being imported from Canada.

Trying to get the exhaust mount sorted. The original A1 mount is about where the orange dot is in the picture below. The red dot is where I'd like to put it if I stick with the current exhaust. I may end up going for a Kerker - if so it will be the KZ1000R model as I can get that a bit cheaper. Hindle is also still on the table (appears they have one version for all models A, MKII, J, R, GPZ1100). 

I would like to weld the original exhaust bushing to the frame using some smaller diameter steel tubing (about 1/2" or 3/4") - the green lines in the photo. I want to get it located so that it works for all exhausts and it seems like the R or GPZ1100 mounting point will work with all systems (I have a bit of leeway with the current system as it's just held with a clamp). Can anybody tell me where the mounting point is on these bikes? Either relative to the points marked in the picture or, better still, measured relative to the swingarm pivot and another point on the frame (bear in mind there isn't much in the way of fittings left on my frame). 

 

You guys are making me want a project bike, lol. 

Quality, Quality, Quality. Love the spoke wheels. 

Thanks guys. Things are slowly coming together. I'm hoping to get the frame finished this year so I can get out the spray gun before spring. Have to get the Zephyr finished as well though!

Looking good Calum. Isn't it fun trying to make everything fit...?  I've changed the old "measure twice, cut once" to Measure everything 45 times and make 2, because the first one is usually not quite right...!!!!

wrote:

Looking good Calum. Isn't it fun trying to make everything fit...?  I've changed the old "measure twice, cut once" to Measure everything 45 times and make 2, because the first one is usually not quite right...!!!!

this is totally true. My mantra is "Want it nice? make it twice!"


Personally, what I like to do for the exhaust mount is weld two threaded bungs into the frame tube (or tabs), and then build the muffler hanger off that. That way if you change the exhaust you can remake the whole mount instead of making an extra piece going between the mount on the frame and the muffler.  Ends up looking cleaner in my opinion and gives you more flexibility in the future. Anything that is frame/chassis related is good to make modular if possible, makes it much lower stakes to change things around when tuning a bike.

Also FYI, its a good idea to have a rubber mount on a stainless exhaust. they move around a lot when they get hot. it can lead to stress cracks if solid mounted.

 

Stainless moves more than any other alloy when it comes to heat.  Makes it a "you know what" to weld as well.

wrote:

Looking good Calum. Isn't it fun trying to make everything fit...?  I've changed the old "measure twice, cut once" to Measure everything 45 times and make 2, because the first one is usually not quite right...!!!!

Only 45 times?

@DoctoRot: That was my original idea and I think Im probably best going back to it. I have cut up the original mount and will use a set of new original rubber bushings from the A1/A2 exhaust mount.

Just thought I'd post a few pics of the thing that has been slowing my progress on this build. My son's almost finished 93 Zephyr.

 

Got the top bracket for the oil cooler tacked up. Fits nicely so will finish off the welding next week. The bottom brackets will be attacked with the grinder and replaced with a couple of fixed nuts and a bracket similar to the top one. 

Do I have enough clearance between the headers and the oil lines? I'll be running braided lines around the side of the block ala sanctuary - quite like that look on modded z's. As far as I know, I'll just need to make sure I add extra oil (the volume of the lines and the cooler) as the oil will drain out when the engine isn't running - is this right?