And finally, Wookie's 82 begins !

Top notch Wookie !

 

howardhb wrote:

Top notch Wookie !


 

Thanks Howard, I have to say that "my little lathe" has more than paid for itself on this project alone (both in cost and time, over outsourcing) The "jury is still out" on the frame gussets at the front, they are so damn ugly that I may replace with tubing 

With the holidays out of the way I have been back in the garage pushing on with the front end. Bars are on and hand controls "mocked up" ( once I'm happy I will get the risers welded to the top tree) I am trying to use as many OE parts as poss so with much modification I have managed to re-use the original headlamp mount, this secured at the top to a bracket between the tree and the ignition switch which will also serve as a mounting point for the nosecone. Will come as no surprise that obviously now the headlamp bucket wouldn't clear the ignition switch so back out with the cutting and welding tools. Lots of fiddling but I am happy with the results (even managed to modify and re-fit the original headlamp adjuster) so onwards and upwards 

 

Those headlight adjusters can be fiddly. I ended up making a new plastic adjustment nut for the 77' KZ 1000LTD out of Delrin, It's cool stuff and you can even cut threads into it. I've also made swingarm bushings for the 78' KL 250 but they are yet to be tested.

Still pushing forward, slowly but still progress. I've mounted a second brake splitter for the clutch & made the mounting bracket for the instruments. I wanted to re-use the insignia, cover on the bottom tree but of course it didn't fit the new front end, so back out with the glue and "hot stapler" 
I am happy with the look and the fit but the paint needs some work, my fault for trying to rush when it's cold and slow to dry.


 

Nothing like making your own parts!
I love fabrication!
Looks Cool!!!

Marty in Buffalo, NY

z1kzonly wrote:

Nothing like making your own parts!
I love fabrication!
Looks Cool!!!

Marty in Buffalo, NYl

Thanks Marty, I have really pushed myself on this build learning to use a lathe and fabricating plastic parts etc. I really hope the end result achieves what I am aiming for

I have been back on the plastic again this weekend working on the nose cone, it's only a cheap universal EBay item but I liked the shape (couldn't believe how hard it was to find something I liked that didn't look like it belonged on a space ship) As you can probably imagine it looked right but didn't "fit for shit" so I am in the process of tailoring it and adding some reinforcement (fortunately it's ABS so easy to work with) My intention is to "manipulate" the plastic so hopefully it will look like it belongs there 

 

Lookin' good Wookie!

Once you've painted your tank, consider protecting it, at the triple-clamp / head bearing area... I've used 6mm / ¼” fish-tank air tubing, split length-wise with a razor blade. 
More than once, I've avoided tears when removing / installing the tank...

H.

 

Thanks Howard, great tip for edge protection 

Cool cowling  i am trying to find one like that .I saw another member here had one on his light blue kz650 ?  i wonder if the diameter on the light house fit a oem kz900 headlamp