Z1100ST Resto +

[needaz1100r]

PS

Can anyone tell me where I put the bloody seat base that I spent a huge part of Christmas welding up?

It's in "that safe place that I will easily locate it from when I need it".

When you find it mate, please be careful of all the stuff I've got there' and let me know!!

[RALPHARAMA]

PS

Can anyone tell me where I put the bloody seat base that I spent a huge part of Christmas welding up?

It's in "that safe place that I will easily locate it from when I need it".

When you find it mate, please be careful of all the stuff I've got there' and let me know!!

Five minutes ago I had to send the 'legs' for my video back to Manfrotto and I was looking for some packing - behind my desk there was a big load of bubble wrap ... you guessed it ... the seat base was in the middle

[RALPHARAMA]

+ one on the complex switch If you need any switch parts let me know and i will send you mine, the housing is smashed from the crash but the internals look ok. On the septic im wiring in "Normal" J switches without all the self cancelling technology

That's very kind of you I have rebuilt it and I guess I'll only find out how good it is when I power up the loom and allied stuff. But I can't do that 'til I've painted the mudguards and head lamp bowl; and I can't do that 'til I've got a head lamp bowl ... though the way it's currently going I think I might end up having to use the square one I have I'm watching a NOS rim for it on flea bay, but I suspect it'll go for silly money; it seems the square headlights were used on ELRs. I'll keep watching flea bay

[Mr Puffin]

No problem Ralph i can put it away just incase Strange how there is allways something holding things up........ I think i spotted a complete headlamp on ebay USA, i can keep my eyes peeled while trawling for parts

[ollie]

what a great job you have made of the wiring Ralph .That switch gear looked a nightmare .
Ralph the headlamp bowl is it the same as a zed thou? if so i will have a dig around im sure i have a bowl somewhere .

[RALPHARAMA]

It doesn't look as if I've done much this week, but I've been hard at it every night.

It's mostly been paint prep, which is slow and laborious.

I did get a new bottom yoke in the post. It's notr too bad condition so I put it straight on.



Now the forks are parallel

The back to paint stripping









Then it was on with the bead blasting



This gives a great key for the paint, but is boring and slow. I can't decide whether to get the mudguards powder coated before I paint them with what ever prettiness wins the vote in my head It will make them less vulnerable to the ravages of the shit on the road being grit blasted by the wheels, but might lose some of the sharpness of the shape.

I have had to stop as I'd been blasting away oblivious to the fact the the left gauntlet had come away from the blast cabinet and now my workshop is in a horrendous glass fog. God along knows how much of that shit I have inhaled Once the dust has settled, I'll refix it. I might smear it with silicon this time

I don't seem to be having any joy getting a proper headlamp for it, so I'll be sticking with this one. I'm pretty sure it's fairly different to the standard Z ones.

[RALPHARAMA]

At the weekend I had to work on Saturday - birthday treat - up at 5:30am to drive to Cardiff to take some pix . Then returned home to do some fettling on a ZX6R. Then off for a lovely meal at a restaurant thanks to some of my oldest friends I did a bit of Zed fettling in between - made the blanks for the fuel tank.

On Saturday I had a few hours to myself so I did some filling on the tank. There was a firking gurt dent in the left bottom on the crease. Like a dick I didn't photograph it first, though there may be a pic further back in this thread - can't remember. Here it is half filled, by half I mean 90% of the bulk but only about 10% of the time



I had to get the etch primer on before the light went completely so I was rushing the filling to the extent that I had to refinish it today

I can't use up my favour points with the local spray booth on priming, so all that has to be done in the back garden. I only did the metal bits in etch primer.



Here's the gloop I used



It's no good for engines as it contains a build (filler) as I discovered the hard way on CB's Z650 engine. I'm using it primarily for protection especially on the insides of the mudguards.



I'm going to paint the insides of the mudguards and under the tank in 2 pack black polyurethane the same as I use on engine cases, which I'll paint separately at home. This means I don't have to hang them up in the spray booth which should make it much easier to apply the candy or pearl - jury's still out on that

Because of my haste on Sunday, I had to do some more filling today to get the front mudguard right and also the tank -





Here's the blanks for the petrol tap and the fuel level sender. The petrol tap one is in aluminium ...



... and the sender one in 3mm foamex. Both are sealed on with RTV



I also finished filling the headlamp shell which was full of rubbed dings from cables etc. I also had to make some repairs to some cracks and brakes using my fairing repair kit. It should look OK when it has some paint on it.



The brake pads arrived today, together with a seat cover:



It's pissing down big time here, so I'll not be walking down to the lockup to get the sponge to try it I had intended to get the seat made up by a professional, but then I thought .... how hard can it be ? I would rather have a 90% OK seat I did myself than a perfect one that someone else did

Anyone , with money, can pay an expert

I gave up on my quest for decent front master cylinder, so today I ordered a pattern job from the wholesalers along with some more T10 bulb holders for the clocks. I've given up trying to get BA9s without wires, but I can get the T10 complete with rubber boot. I have also at last managed to find a place that sells non-insulated butt connectors. They're a bit dear, but cheaper than machining them out of brass bar on the lathe Annoyingly they won't be here 'til Monday, which means that work will have to stop on the clocks over the weekend.

I managed to fuck up the fuel gauge dial face by trying to clean it with a cotton bud soaked in IPA Trouble is the sods are as rare as rocking horse shit. The clocks on the earlier ones were quite a bit different and I haven't seen the same clock's on any other models These things are sent to try us I might have a go at getting the front brakes build this weekend and if the weather's nice perhaps even the hi build priming and rubbing down

[paul doran]

Ralph can You post a picture of the clocks in case I may have similar You can have

[RALPHARAMA]

Ralph can You post a picture of the clocks in case I may have similar You can have

That's very kind of you Paul



As you can see she has a few miles on the clock - the recent of which were under huge duress with maximum unkindness and virtually no love

Still she's getting lots of TLC now!

[RALPHARAMA]

Had a lot of frustration last night and this morning trying to figure out why the wheel went tight when I tightened up the spindle nut.



I tried all sorts but eventually a thin shim ( machined out washer) did the trick

I bought a beautifully cheap new pattern master cylinder after trying loads of genuine one that were pre- knackered. They all seemed to be corroded in barrel - and I'm not wasting good money having them powder coated, only to discover that they won't bleed up.



The HEL lines that have been in my office for what seems a very long time were finally dug out. The first job was to give them a good polish - all stainless must shine - it's the lore



I fitted all the lines on the front but decided to fit the headlamp securing frame before filling with fluid. Like everything of the bike, it had all been bodged so I decided to make some new fittings for the rubber mounting, as I have bits of material, time and no money Besides as I've said before - any one can buy stuff Here's the two 'top hats' for the upper mountings



... and here's one in the rubber ...



The bottom one is more in view, so I decided to make that one a bit more fancy and used some 316 SS



... I decided to go the whole hog and use a countersunk cap screw ...



... and here it is in situ ...




Seemed like everything was going well? I thought so .... I decided to offer up one of the uber cheap pattern indicator stems I had invested money in. Looked great - really good Much better than I expected for the pitiful amount paid for them Then I decided to see if I needed to trim some of the stud off to clear the head lamp. Now I knew the headlight mounting frame had been bent by a monkey to take the square head light; but I hadn't appreciated how fucked up it all was. The headlight really doesn't fit at all and now I know why there were so many gouges in the headlight shell.



I am going to have to either make a completely new headlamp bracket, which won't be easy or get a headlight that fits. It's not the same as the early Zeds; It's round at the front, but the back is sort of squarish - I don't know if Js or others had the same headlight.



I crack on with other bits tomorrow

[RALPHARAMA]

Decided it was time to fit the foot rest hangers. Couldn't remember where the bolts went and was unable to find any that looked as though they were original so plucked some stainless cap screws from the rack, cleaned the crap off and polished them. Also polished some plain washers as well.



Then I realised I had only remembered to plate one of the front foot rest hanger pins, so I spun a bit o stainless up in the crappy chinese lathe:





So having sorted that I realised that I couldn't fit the right hand one until I had rebuilt the rear brake master cylinder, so I stripped that and fed it to the ultrasonic bath together with the disassembled petrol tap. Was a bit shitty but looked better for a bath - don't we all



Here's the left fitted, but I had to order some big washers that go against the footrest runbbers, though now they've come they're not plated so not sure whether to fit them. The only reason I bought them was because I couldn't be arsed replate the originals having forgotten on the last batch



I can't get the bloody airbox on cos the rubbers are all hard grrr so that'll be another big bag of money to Fowlers or Z Power They are at least available so I shouldn't winge too much - should I



Not sure why I photographed these



Bastard front brakes have been causing me all manner of grief. I have bled up sooooo many bike brakes over the years, even ABS jobs and I can honestly say that nothing ever gives as much fecking grief as Big Zed front brakes, and these feckers really take the pigging biscuit As you will know if you've been reading this from the start, I wasn't exactly careless with rebuilding the calipers - not cutting massive corners on anything. Brand new pattern brake master cylinder, tried to bleed it .... wouldn't have it took the calipers off the legs, undid the splitter so we can play 'chase the air bubble' and other such failsafe bleeding games , but it still wasn't going hard. Tie the lever in and leave it for days on end .... still softer than a left wing faggot Rang up the wholesaler to complain about the fact that the numpties had sent me the wrong frigging head light - yeah I really wanted a 35/35w head light . They then started lecturing me about priming a new master cylinder ... like I was fixing my first M***D So I though I've got a complete working Triumph system down the lockup, I'll try the master cylinder from that. That won't bleed up either

I'm not sure that the calipers are entirely in the correct position with the disc, not that that should make any odds the the bleeding really.





Having heard less than favourable reviews of these stopper on here in the past, I think it is time to look for some new calipers to throw more money at. Perhaps 1100 zephyr? Any ideas ? I did contemplate the Triumph (re-badged Nissin) but the inside pots hit the wheel spokes so that's never going to work Did look at Pretechs, but they are way out of my price bracket as are AP lockheads and brembos

[RALPHARAMA]

As you could see in the last pic, I left the Triumph Master Cylinder strapped up and this morning it is much healthier. Temptation is to leave it now it works. If I do I'll have to make a pretty reservoir - probably something 'custom' available.

[nanno]

What I do with calipers on the Zed, if they don't bleed properly, is to push back the piston manually, that way, you push most of the air and a lot of fluid back. You do it 3-4 times and the feel is as hard as it can get.

Cheers,
Greg

[RALPHARAMA]

A lack of work and a threat of sunshine has sent me into the back garden with an air line and some bits In reality it's too fecking cold to paint, but I larded some hi-build primer on the bits requiring painting. I did have it in mind to mask up the tank and mudguards to fire some 2K polyurethane black on the insides for protection, but even the the hi-build, which is two pack, is still taking for ever to harden and if I stick masking tape on it, it'll either never come off or bring the paint with it - neither a great result I was also finding the very low sun very difficult to spray in - it was pretty much blind, I really couldn't make out what was wet and what wasn't. The paint was going on pretty lumpy, which felt as though it was a bit thick, but I thinned it to the maximum suggested in the data sheet (10%) when using fast hardeners. I dapped on a quick guide coat from a rattle can, which also didn't function very well in the cold, but will be fine for flatting to.

[Ginger Bear]

Any good Ralph

http://www.ebay.co.uk/itm/KAWASAKI-GPZ1 ... 5952797%26