Z650 into 810 project

Crofty · #31 PostAuthor: **Crofty** » Wed Sep 28, 2011 8:09 pm

Took delivery of the cams I am going to try last night, they run very close to the bucket holes, but with the top caps installed they seem to miss OK, without they can be pushed sideways and touch.

Joy 2 cams

Close to edge

pertonpc · #32 PostAuthor: **pertonpc** » Wed Sep 28, 2011 8:34 pm

Hi Jim

I think you are pushing the boundaries and going where few 650 owners have trodden on this one.

Can we please have a video when this monster comes to life.

I would love to see a bigger zed try and have it for breakfast!!

From Mark

Crofty · #33 PostAuthor: **Crofty** » Wed Sep 28, 2011 9:32 pm

Mark, I think a few have done more than this will be, I will definately be doing a start up vid. I am waiting for Royalratch to get on with his engine, if its as good as his chassis stuff, it will be nice.
He's been quiet for a while so I expect he is busy on it.

j.b · #34 PostAuthor: **j.b** » Fri Sep 30, 2011 12:15 pm

keep up with the good work jim, your attention to detail with this motor is inspiring :brav2

Crofty · #35 PostAuthor: **Crofty** » Fri Sep 30, 2011 1:16 pm

Hi JB, How are you going? What boost have you turned your machine up to so far? I still intend to catch up with you, but work/family things keep me from doing it.

I have had the head you sent cleaned up and the scratches to the chambers should be OK. I plastigaged the joy cams this morning in that head and all 8 journals are in the 0.10mm clearance range, I ended up having one exhaust stud mount repaired and 1 helicoil for a cam cap bolt (lucky, normally more are fooked), As i keep saying i just need to save up for the rest of the headwork and parts, but should not be long now.
I have a frame coming from Royalratch, but it looks like a D (SR) model, but know someone who can brace and mod it to fit ducktail, it should accept rear master cyl for disc rear brake. Crofty

j.b · #36 PostAuthor: **j.b** » Fri Sep 30, 2011 4:02 pm

no worrys mate, i'm pleased the head is looking like a good one

i'm just running mine at 14psi :twisted:

its still got huge grin factor, although i can see a new head gasket needed in the near future

Crofty · #37 PostAuthor: **Crofty** » Fri Sep 30, 2011 4:46 pm

At least you know how they all fit together. My mate has a 650 he bought as a barn find ex usa and it has the same broken boss that the gear lever end locates into. Not an easy repair, we have a very good welder in York and he is finding it hard to machine around after to allow spring to locate over the boss. Any ideas?

j.b · #38 PostAuthor: **j.b** » Fri Sep 30, 2011 7:05 pm

he has done well to get a weld in around there, can he not use a die grinder to re profile the boss. it is a very thin wall but doesnt need to be 100% accurate so long as the spring can fit over it

Crofty · #39 PostAuthor: **Crofty** » Fri Sep 30, 2011 7:33 pm

Actually I think thats it, j.b. he cant get to the rear side of it, towards back wheel. He was thinking of welding it solid then drilling it out and die grinding it

j.b · #40 PostAuthor: **j.b** » Mon Oct 03, 2011 6:51 pm

sounds like a plan jim, or theres always my (bodge) fix which seems to be holding up ok so far

Crofty · #41 PostAuthor: **Crofty** » Wed Oct 05, 2011 11:40 am

I think your bodge is actually OK, once the outer cover is fitted the shaft is quite well supported.
I have been given a D3 frame (thanks Royalratch), I will need to do a few mods, to fit ducktail which D models did not have, but its going to be braced up as well. A full dry build wll be required on this project.

Trying some cases and bodywork on

Early 1980 D3 model

Crofty · #42 PostAuthor: **Crofty** » Wed Oct 12, 2011 7:22 pm

Quiet day today as its peeing down and no one wants their bike fixing, so into shed and more hacksaw and grinder work. The D model has a seat stay slide that runs parallel with the frame tube it sits on. The other models B,C and F have ones that angle away. So I cut and realigned it. The lower lh exhaust/rear footpeg bracket has bad rust, but will get it welded up. I toyed with the idea of removing altogether, but then it makes it hard to convert back to std. Mind you I think thats lost now anyway with converting from D type set up.
So far I have lopped off the steering lock, realigned the seat slide/stay bracket, removed the rear loop that the mudguard bolts to and taken off the seat hinges.
j.b. has found me a frame with the rear bits intact that act as seat buffers etc, which I am going to go over and collect (check out the frame its in the breakers backyard/vegetation). Then I will remove these to weld onto the D frame, good chance to eyeball his turbo too

Donor frame for bracketery.

F frame showing angled slide.

D frame parallel.

Cutting slide to allow bending.

Ready to weld.

The only bad rust on the bike is on this bracket.

Crofty · #43 PostAuthor: **Crofty** » Sun Nov 06, 2011 5:38 pm

Drove over to jb's house today to pick up my frame section. It has copped a fair whack, but I can use the seat brackets off it, jb also gave me the rear loop off his turbo that he cut off to fit his KH rear cowl. My special will be honoured with some of the 'turbo's' genes when it gets welded on.

And jb, heres a shot of Gary's repaired g/box selector shaft repair

Never realised how big his back tyre was till I saw it in the real and it can let go at 100mph!

No pics of my frame section, tho it can be seen on the floor of the shed to the left of the bike, will put some on when I actually do some welding.

j.b · #44 PostAuthor: **j.b** » Mon Nov 07, 2011 4:01 pm

nice to finaly meet up jim

very tidy repair on your mates' crankcases

sanderz · #45 PostAuthor: **sanderz** » Mon Nov 07, 2011 10:27 pm

Keep it goin' Crofty, be a cracker this :up

Crofty wrote: I toyed with the idea of removing altogether, but then it makes it hard to convert back to std. Mind you I think thats lost now anyway

- Go for it, its your bike, do it how you want to.

Z650 into 810 project

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