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GB's Modded Z900 now on a runaway budget!

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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Ginger Bear
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#256 PostAuthor: Ginger Bear » Tue Mar 24, 2015 8:17 pm

Had these back from powdercoating last week.

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Oilways have been flushed/pulled through, but were free of any blasting media. I guess it must be because they were chemically stripped before vapour blasting, which removes the oil residue as well.

All threads have been rinsed with brake cleaner, then blown out with the airline. I plan to run a tap down 'em tomorrow & once I've repaired a couple threads I can start putting it back together. :sou :sou
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# 104

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#257 PostAuthor: Hinckley » Tue Mar 24, 2015 9:30 pm

Very impressed GB, the finish looks awesome :up

Does it add much thickness around the frame mounts?

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#258 PostAuthor: Ginger Bear » Wed Mar 25, 2015 7:41 am

Doesn't appear to have added anything significant to where it bolts up to the frame, the acid tet will be when I refit it all in the frame. :??

Powdercoating appears relatively thin, I'll try & post a pic of the engine No. later, that demonstrates the powder has not been glooped on, as it is by garden gate powdercoaters.
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#259 PostAuthor: garyd » Wed Mar 25, 2015 8:27 am

GB, did you prep and mask all the faces or did they?

And do you know what was used to mask them?

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#260 PostAuthor: Ginger Bear » Wed Mar 25, 2015 8:38 am

Gary, I delivered oily shitty cases. What you see is how they were returned.

I have no idea what they use to mask them, sorry. :(
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#261 PostAuthor: Ginger Bear » Wed Mar 25, 2015 4:21 pm

Spent some time preparing my crankcases for reassembly.

Somehow I'd missed this repair when I pulled the cases apart. :shock: :shock:

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I guess it's the result of bolting the cases together without having all the locating pins correctly located.

The repair looks to be well done, but with no locating pin fitted, there is every chance the bearing could move & cut off the oil supply. There's no way I fancied riding around with that in the back of me mind, so I set to work sorting it out.

Luckily I was able to steal the pin from the kickstart shaft, as that will be redundant. I used a steel rule pressed either side of the adjacent pins to mark a couple of lines, then using verniers as a scribe marked the centre line, then punched it......... Very carefully. :ek

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With a bit of adaptation I got it all squared up, ready to drill.

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After a little arse clenching, the hole was drilled & pin fitted. :sou


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They even line up!

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A much easier repair was to fit this TimeSert into what was a damaged thread.

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#262 PostAuthor: ADRIAN H » Wed Mar 25, 2015 5:26 pm

Well done that man, (would not have fancied drilling the casing myself). This bike is going to be lovely. :D :D :D
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#263 PostAuthor: Ginger Bear » Sun Mar 29, 2015 5:35 pm

Had an update from Buzzard. :sou

2 exhaust seats finished, blue engineers dye shows up the 45 degree seat after cutting and lapping in with fine paste (I never use coarse or medium paste to aggressive and leaves tram lines on valve face) The shinny surface either side of blue seat is the 30 degree and the 60 degree angles. Nice finish. Buzzard @ the buzzworkz.


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I haven't been quite so busy, but did manage to 'dry fit' my Saisei sourced PMC crankcase bolts & sort them into the right sizes ready for reassembly which will hopefully be this week.

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#264 PostAuthor: Paul Whitehouse » Sun Mar 29, 2015 7:33 pm

Brilliant work Steve...it's going to be a belter. Great work by Buzzard as well. Looking forward to the next update :)
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#265 PostAuthor: Ginger Bear » Wed Apr 01, 2015 7:08 pm

More progress!

Crankcases have now had all the gubbins re-installed (except the kickstart shaft) & been bolted up. I did start to take pics, but then must have been overcome by the excitement of progress. :roll:

Here's the only pic's...

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Once done, it was laid on it's side & the frame lowered over, a few mounts fitted, before being turned back upright and bolted in permanently. Whoever came up with that method, deserves a medal!!

Tonight, resisting the temptation to steam ahead, bolting freshly re-finished parts to the frame & motor, I've been stripping shitty dirty brake calipers.

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These will go to Simon at Flying Tiger, to be ceramically coated. Hopefully they'll come back looking something like these little beauties that can be seen on Simons FB page.

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#266 PostAuthor: Is Vic There » Thu Apr 02, 2015 9:57 am

This is a great build, would have thought twice about drilling the crankcase, it would have been a Stella and thinking moment for sure!

Love the brakes mate, nice.
Z1000R ELR, Z1100R ELR, GPz900R A1, GPz750 Turbo, Norton F1, Harris Mag 2, Harris Mag 5, Yamaha YZR750SP, Triumph Steve McQueen, Suzuki RGV250 Sheene Rep, Suzuki RG500 Walter Wolf, Suzuki RG250 Walter Wolf, Aprilia RS250, Yamaha YL1, RG500. H**** NS400.

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#267 PostAuthor: ZedHead » Thu Apr 02, 2015 11:21 am

I can never get over the skill of the people on this forum. Great build!

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#268 PostAuthor: Ginger Bear » Thu Apr 02, 2015 7:49 pm

ZedHead/Dave,

I'd best not let my wife read that comment, she just thinks I'm a smart arse. :roll:

Vic/Ian,

There was a lot of thinking FIRST, followed with a little Stella or two. :sou :beer

Anyhow, tonights couple of hours in me favourite room have seen the calipers fully stripped & cleaned.

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Next stop, Simon at Flying Tiger. :D

Swinging arm also bolted in.

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#269 PostAuthor: Hobbo » Thu Apr 02, 2015 8:13 pm

Ginger baby



Your a top notch engineer Luuuuuuuuuurvvvvvvly



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#270 PostAuthor: ruffle » Fri Apr 03, 2015 10:24 am

That powder coating looks good and if you can send them 'shitty' cases and they come back like that then I'm tempted to follow your lead on the Harris motor.

Are you going to powder coat the block and head or stick to paint?


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