Z1100ST Resto +

[RALPHARAMA]

I have at last decided that the frame is untenable, without a decent one to correct it to. I have bought another from a breaker for a huge bag o money. Having got the 'new' frame, I now know how bad the old was! The 'new' frame is from an A1 and is a British frame complete with reg plate. As it is a 'W' reg I'm going to apply for the V5; has to be better that and 'A' reg! I have had it grit blasted and it's now at the powder coaters along with the seat base.

Having finished bead blasting the head I noticed there was some damage in the bit where the bucket sits on one valve-



At this late stage I decided to carefully dress it and keep my fingers crossed!



I decided to polish the ends of the cam cover. They were surprisingly scabby and I had to remove plenty of material with the 2" air sander first



came up OK in the end



Next was time for masking up the engine for paint and I started with the cam box



LAst time I sprayed a head I found the old plugs I used to fill the plug holes made getting paint into the fins even harder that it was already, so this time I machined up some placcy plugs; only bummer was that the only stock I had was 50mm round bar



Just the job when screwed in though !



The carbs were pretty shitty;



I had originally decided to paint them, but after I had used paint stripper, jizer and a swim in the ultrasonic tank I decided that they were OK naked. I don't like painting carbs; to make the paint stick well they need to be bead blasted, and whilst I have done it in the past, I don't like blasting carb bods



In a moment of madness I splashed out on a genuine set of carbs rubbers:



Saturday morning I bundled all the paints, spray guns etc in the van and all the masked up engine bits and drove to one of my customers factory where they have a spray booth they let me use from time to time. I used an etch primer with no build or filler making it non-porous. Was a very strange paint to use; although it went on very thin, I used 500mls of mixed paint. I kept the top coat pretty thin, but still massively thicker than the primer, but only actually used about 300mls. Not sure that makes any sense really!





In the van ready to head home



I'm now removing all the masking; doesn't take as long as making it up, but takes more time than you'd think!

Took a shed load of wire wheeled/bead blasted parts over to the platers today. They said they'll be at least a fortnight

I took all the gears from the 1000J ltd box I had and fitted them onto the shafts from the eleven.

Hopefully the frame will come back soon and the build can begin,

[Pigford]

Good work Ralphy - and nice photo's & "talk thru' too"

[Al]

Has someone bottomed out one of the cam cover bolts and blistered the bucket well inwards??
Hard to tell from the pictures.

I know not all the carb bits are pictured in the photo above but i dont see the pilot jets and the small alloy plug which covers them. If youre going to get trouble with them it will be becuase the pilot system is blocked.

AL

[Gavin]

nteresting reading I have had Two Z1100 shafts in the past and found them a solid workhorse apart from The Bracket that holds the sidestand, it cracked at the toe of the weld though the frame, once welded it was ok.(Care needed when setting position of bracket before tacking). Also the upper suspension mounts appear to be natural collectors of water, as mine needed plating up and welding, on both sides.

[Ginger Bear]

Looks like you've been a 'busy boy' Ralph....... Keep at it!

[pertonpc]

Great work Ralph
Can't wait to see it going back together now.
From Mark

[paul doran]

Ralph what paint stripper are You using
I take it it is not Nitromoors

[RALPHARAMA]

Ralph what paint stripper are You using
I take it it is not Nitromoors

Nitromors used to be great 'til we got the new improved 'safe' recipe that doesn't strip paint

This is the stuff I use:



I get it from the paint factors that sell me most of my paints. It's good gear, but you need to get it from professional suppliers - you can't have DIYers using products that work like in the bad old days

[RALPHARAMA]

I finally de-masked the engine bits and sat them on top of one another - to see what it'll look like! It's been a lot of hard work to get this far. I am waiting for a lot of the bolts to come back from the platers before i can start the motor rebuild. I haven't got the new cam chain yet - I wanted to go to the annual Expo at NEC today before ordering the chain and also carb kits. Glad I did as I have now signed up with a new disty who'll do me a better deal on the cam chain. There was a lot of temptation at the show, not lease of which was a really sexy new electro/hydraulic bike bench, I was weakening toward signing a finance deal for the show deal of only £1700 + VAT, when I thought about the excruciating pain I would sustain in the groin area if I came home and had to admit to CB that I had signed such a financial commitment for a toy. I was struggling about how to answer the "what's wrong with the one you've got already?" and had a feeling that the "but the new one is much shinier and will go up and down with out my taking pretty much the only exercise I ever get...." so the new black and red electric/hydraulic bench will just have to mine in my dreams ... maybe next year ... anyway back to the shafter ...





I dug out another set of carbs from the loft which were from a 1000J Limited I got ripped off on (long and bitter story)

Luckily the diaphragms look pretty good, which has cheered me up as the cheapest patterns ones I can lay my hands on are £30+VAT a pot and I am not entirely sure about the quality. The only other realist option would be to send them up to NRP to get the actual rubbers changed on the slides - still £30/pot + VAT, though the quality may be better. The jury is very much out on the carb kits, but I think they will most likely come from the US. The Ltd carbs have the older cast ally tops. I cleaned one up and am trying to decide which to use (original are chromed steel-inner zinc plated)



Yesterday went over to the powder coaters and picked up the seat base, a couple of brackets and the frame - YES the FRAME!!!!






Next job was to reassemble the rear bevel box. The bearings had to be remove before I could bead blast for powder coat. Not greatly pleased with the powder coat on the casing, but it's too late now.



It;s a bit tricky getting the bearings in and as tolerances seem a bit tight in this I decided to make some special tools to refit these races.



See some keep fit going down on my organic machine hacksaw The large diameter bar nigh on creased me

I spun the parts up on my cheap chinese apology for a lathe> I finally overcame my natural meanness and bought a throwaway tip tool and a handful of new tips. I have to say that it really is the donkey's privates.



Here's the finished tools.



and here's the bigger one being used. The smaller one is in two bits as the handle bit can have different bits added as and when I make them as I need them. Thinking ahead eh







The cap screw that held the swinging arm holdy in plates for the bearings needed replacing with shiny stainless, but I'm too tight to buy 'em. I get the cheap ones and machine them in the lathe and them polish. Loads cheaper and more satisfying



The bench is looking happier now

[pertonpc]

Wow Ralph
Some ingenious stuff going on there mister. Also not bad going to be working on so many different aspects of the build simultaneously without getting in a muddle.

Who said we can't do multi tasking??

[KeithZ1R]

We can't tidy up

[Z1parR]

Who said we can't do multi tasking??[/quote]

Women said that Mark that's who

[coldsummer]

Very impressed with your persistence and attention to detail with this build Ralph. I would have consigned it to the back of the 'naughty bike shed' long ago.

[RALPHARAMA]

Wow Ralph
Some ingenious stuff going on there mister. Also not bad going to be working on so many different aspects of the build simultaneously without getting in a muddle.

Who said we can't do multi tasking??

Not sure about the not getting in a muddle

[paul doran]

really good updates Ralph keep at it