Testarossa's 78 KZ1000 Fighter Build

i had no trouble drilling out he 2 baskets i did. i did have trouble fitting the ape sleeves over the ape rivits though. i didnt have a press so i was afraid i may get them 1/2 way on and get stuck. i ended up massaging some material off of the sleeves ID. so they would just slide over the rivets.
i had my friend clamp it back together and weld it for me.
i also massaged the spring cases, they get deep grooves warn in them, so i smoothed over the grooves. i had 1 balanced after the upgrade. he said it was only out 2 grams to start with. he said some of the new ones are out as much as 9 grams.:woohoo:

I'm glad you were able to get back to it. I need to do this at some point as well. How did the engine cleaning go, any pics of that? As far as the broken bolt, it looks like you need to find an EDM machine.

Ask and ye shall receive.







I still have a little work to do on that base gasket surface on the last picture.

Here's that last broken bolt that I discovered the other day.



It WAS down in the bottom of that hole where the dowel pin goes.



So I need an EDM do I? How about a left handed drill bit. I bet that thing didn't drill 3/16" into that bolt before it unscrewed itself.



I also got the clutch basket back together tonight.

Thats great the broken bolt came out easy for you. I imagine that it did not shear during disassembly? Your clutch basket looks nice. How did you solve the drill bit eating issue? I've been eating bits gun drilling some stainless bolts on the lathe..

The cases look good... did you use scotchbrite disks on a die grinder on the base gasket surface?

porchev914 wrote:

Thats great the broken bolt came out easy for you. I imagine that it did not shear during disassembly? Your clutch basket looks nice. How did you solve the drill bit eating issue? I've been eating bits gun drilling some stainless bolts on the lathe..

The cases look good... did you use scotchbrite disks on a die grinder on the base gasket surface?

You're right, I didn't break that bolt. I guess it broke due to vibration. Heck I didn't even know that it was in there until Saturday.

As for the drill bit eating, I punted. I just used my Dremel tool with some green grinding stones and ground the holes out. I did burn up 4 stones opening 3 holes.

Not scotchbrite but close. I used one of those abrasive fibre gasket removal brushes. Think cup style wire wheel, but with plastic bristles.

Now on to your drilling problem. Of course, I have questions.
#1 what type of stainless, 304, 316, 420, 17-4, 18-8, etc? I think most off the shelf stainless bolts are 18-8.

#2 what diameter hole, and how deep?

#3 what type of drill/drills are you using? Just send me a close up picture. You are starting the hole with a spot drill, and then a short drill aren't you?

#4 how fast are you turning your spindle? Stainless is tough (wears tools fast) and it's usually gummy/stringy (chips don't break, you get long continuous chips that are good for loading up the drill.)

#5 what are you using for cutting oil or coolant?

As usual I'm happy to help, and I'm sure to have more questions, but I may start a new thread with the answers.

It's odd that i did not have to drill my basket holes out as u did? my rivets fit the existing holes.
did u find that the spacer bushings (rivet sleeves)were extremely tight to fit over the rivets? i would have needed a press if i hadn't reamed out the sleeves.
nice to here the bolt came out easily for u.
Keep up the good work.

mark1122 wrote:

It's odd that i did not have to drill my basket holes out as u did? my rivets fit the existing holes.
did u find that the spacer bushings (rivet sleeves)were extremely tight to fit over the rivets? i would have needed a press if i hadn't reamed out the sleeves.
nice to here the bolt came out easily for u.
Keep up the good work.

Yeah Mark the new rivets were quite a bit larger in diameter than the stock ones. About 0.060" or 1.5mm larger. And yes they were a rather tight fit. I would call it a light press fit, but I'm not scared to press them in. I have a 50 ton press at work. If I screw up at the house, then I drag 'em to work and big red solves all my problems.

testarossa wrote:

mark1122 wrote:

It's odd that i did not have to drill my basket holes out as u did? my rivets fit the existing holes.
did u find that the spacer bushings (rivet sleeves)were extremely tight to fit over the rivets? i would have needed a press if i hadn't reamed out the sleeves.
nice to here the bolt came out easily for u.
Keep up the good work.

Yeah Mark the new rivets were quite a bit larger in diameter than the stock ones. About 0.060" or 1.5mm larger. And yes they were a rather tight fit. I would call it a light press fit, but I'm not scared to press them in. I have a 50 ton press at work. If I screw up at the house, then I drag 'em to work and big red solves all my problems.

glad it all worked out for u.
not having a press i had to take an alternate route.
Sometimes have to take a dif approach to my projects than u guys with all the tools. I wish i had them , but ....
i am making a steering damper bracket now. i was just thinking... i have to do this job with what i have on hand or can attain, rather than doing it the best possible way. sometimes this way ends up more function, than form. but i have to do what i can myself, to keep the cost down, then job out the rest.So i put my grinder back to work again, instead of someones mill.lol

Late to the discussion but,

Why the PVC and not a water seperator/regulator? It's humid like a jungle in NJ and I'm battling moisture too.

The idea is to allow the air to expand and cool before it gets to the airline. When the air cools, it allows the water vapor to condense, then run down the bottom of the pipe to the two drop lines. I also have a water seperator/regulator at the tank which catches alot of water, but you would be surprised at how much those traps caught when I was painting. I also have a dessicant filter in the airline right at the paint gun.

BTW as per the previous discussion, PVC is not really safe for airlines. My setup was regulated down to 40 psi before the PVC manifold that is pictured.

Oh yeah, I forgot to mention. My system worked very well while painting. I had zero water issues.