My Ultimate Zed

[Zomerset Zed]

Thanks for the photo Ian, I have been trying to locate details of what others have done here for a while now. This will give me something to do over the winter

[Zomerset Zed]

Haven't been able to get too much done on the Zed recently as work getting in the way!
But i have done the following:

Cut and shaped 25mm tubes to brace the frame:



These took quite a bit of work with the die grinder to get a nice neat fit and a half decent weld prep. I then tacked them in place in the frame:













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Also got me some R6 USD forks and some TEC piggy back shocks to fit:







Amazingly it looks like i do not have to modify the steering stem to fit, just fit some new taper roller bearings and get a new top yoke designed and machined to fit. I may have to look at extending the forks a little bit hopefully all internally.

I will be fabricating new top shock mounts to move them forward by about 90mm and designing and making some new ally mounts to weld to the swingarm to get the look and geometry correct.

This will bring the distance from the swingarm pivot to the lower shock mount centres equal to the distance between the swingarm pivot and the top shock mount centres. This will ensure a slight rising rate to the wheel travel/spring force relationship.

Before i cut any metal i need to get the ground clearance right so its not too low or high at the rear. Anyone know what standard ground clearance is between the bottom of the frame rails and the floor?

[snotie1965]

This looks like it will be a good Z !!
I just measured my uni-trak bottom frame rails directly under the clutch cover ,bike bolt up-right and it is approx 230 - 240 mm and that is from the bottom of frame rail to level flat floor , but i am sure someone on here will give you the Z measurments ,but i cant see it being loads different ?

I hope that helps you a bit ,,,,,,,,, Andy

[Zomerset Zed]

Cheers Andy, I'll go with 230mm then

[Zomerset Zed]

I thought it was about time i made a long overdue update:

Excuses: work, not being in the country, shite weather new bike etc. blah, blah

What have i done?

Clutch basket stripped, blasted new APE repair kit installed. I did do a full photo step by step instructions for this but i have lost on old phone. But it was fun and all done "in-house":





Holes have to be drilled out precisely as pins are larger diameter and then spacer collars heated with blow torch and hammered like fuck onto the pins. Then all needs to be clamped up and ends of pins welded up.

Next up - More frame mods

[Zomerset Zed]

Again i lost all of the step by step photos, so here are the nearly complete results:



Tube bracing to reduce head-stock twist



Secondary plate welded in to create a box to reduce head-stock twist



Plating to undo someones previous "enhancements"



Rear horizontal members now welded in to reduce twisting of the cradle at the rear



Upper and lower chain run "channels" created to allow fitment of 6" rear wheel. Note how i have cunningly incorporated a frame brace into the deal. Something which Sanctuary do not do. Tacked into position awaiting parts to be made to complete the chain run and rear wheel placement.



RHS bracing to strengthen up rear "sub-frame"





Cut up sprocket cover (it was split anyway) to get chain run in.



No expense spared high tech drilling jig for new top shock mounts



Now waiting for top shock mount so i can position in frame and weld in place

[Pigford]

Looking good Ian Lovin' the chain run mods

[Zomerset Zed]

Looking good Ian Wink Lovin' the chain run mods Twisted Evil

Thanks Pigford, but who the fark is Ian

I used the clutch kit you traded with me BTW. so well happy with that

[Ginger Bear]

Looking good Ian Lovin' the chain run mods

+1

[Zomerset Zed]

This is what i am doing to mount the R6 forks:


Top yoke, bar clamps, new stem and other bits and bobs are being CNC machined at the moment. I am using the standard R6 bottom yoke.

I have procured an R6 front wheel and monoblock radial calipers, so once i get the machined parts back i can build up a complete front end. Just need to find some discs i like at a reasonable price.

[Zomerset Zed]

This is what i am doing to support the longer output shaft:





I am mounting a ball bearing inside the sprocket on a new +25mm output shaft which will have an R1 spline cut into it rather than the Z1000 spline to mount the sprocket on. This will allow me to run standard R1 sprockets front and back in either 520 or 530. It will allow me to get the chain alignment spot on in practice by adjusting the length of the spacer between the sprocket and the gearbox bearing. When/if i want to change the gearing or when the sprocket wears, i just buy a new standard R1 sprocket. I am also fitting a case saver and one of Falk Stumms hydraulic cylinders.
All this also fits under the standard housing, so externally looks like a bought one

[Zomerset Zed]

These are next on the "to get machined list":





Vague copies of Sanctuary items which allow you to remove swingarm spindle and keep footpegs in place.

[Zomerset Zed]

[Zomerset Zed]

[Zomerset Zed]

Decided to do some painting of some parts myself. Needed to paint bottom yoke prior to assembling with bottom taper roller and seal. Wouldn't want to have to remove the bearing and seal and keep intact to paint again!!