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Money pit 3 - ELR - Finished at last
Moderators: KeithZ1R, chrisu, paul doran, Taffus
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Geoff Meager
- ZedHead
- Posts: 1140
- Joined: 5th Apr 2007
- Location: Dereham. Norfolk.
I thought it was time for an update. I picked up an engine from Jack last weekend with 1170 barrels, was only going to spray paint it, but I got carried away and totally stripped it 
so the crankcases etc are off to get powder coated on Monday.
I had to get the frame powder coated again, as I had some brackets for the oilcooler and seat unit welded on, so I should be able to start slowly putting it together next week. Idealy, considering the weight of the engine, I want to wait until the engine is rebuilt, so I can drop the frame around the engine.
I think I have all the bits to get it to at least the rolling stage, with exhausts fitted. The only thing I have to get made is the instrument bracket, so I will be speaking to Andy who made my yokes in a couple of weeks.
I will put pictures up when I get the stuff back and starts looking like a bike and not a lego kit.
Cheers Rob
so the crankcases etc are off to get powder coated on Monday.
I had to get the frame powder coated again, as I had some brackets for the oilcooler and seat unit welded on, so I should be able to start slowly putting it together next week. Idealy, considering the weight of the engine, I want to wait until the engine is rebuilt, so I can drop the frame around the engine.
I think I have all the bits to get it to at least the rolling stage, with exhausts fitted. The only thing I have to get made is the instrument bracket, so I will be speaking to Andy who made my yokes in a couple of weeks.
I will put pictures up when I get the stuff back and starts looking like a bike and not a lego kit.
Cheers Rob
Last edited by Robw on Sun Apr 05, 2009 8:27 pm, edited 1 time in total.
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
-
Bill Newman
- 100Club
- Posts: 459
- Joined: 27th May 2007
- Location: Ipswich
As promised here are some photo's. It is now a rolling chassis 
, all the brakes are bled and work well. I had to strip it down and send it away to get the frame powder coated as I had brackets for the oil cooler and seat unit welded on the frame.
Although the forks are 43mm, I have tried to keep the front end similar to the original, by removing the headlight brackets from the stanchion tubes, then re-welding them to some metal tubing I got from Mallard metals.
The backend has Works performance shocks fitted with some bushes made to take into account the wider ZRX swinging arm.
The seat unit is from Kipkawa, which considering you got an original uncut mudguard and seat, for an excellent price (less than £200).
The crankcases are due to picked up from Aerocoats (excellent service) which are near Beccles on Wednesday. I have just ordered tons of stuff from my local dealer (Orwells), Z Power and Debens, so hopefully I will be able to start rebuilding the engine this weekend.
I have just sat on the bike and the seat is quite wide, so hopefully it is more comfortable than the 1000 Katana I had.
The bike in the background is my 350 LC which is feeling sorry for itself at the moment as it feel over and broke the pro am fairing screen and brake lever
Thats all for now I will post some pictures of the engine parts when I pick them up.
Rob
, all the brakes are bled and work well. I had to strip it down and send it away to get the frame powder coated as I had brackets for the oil cooler and seat unit welded on the frame.
Although the forks are 43mm, I have tried to keep the front end similar to the original, by removing the headlight brackets from the stanchion tubes, then re-welding them to some metal tubing I got from Mallard metals.
The backend has Works performance shocks fitted with some bushes made to take into account the wider ZRX swinging arm.
The seat unit is from Kipkawa, which considering you got an original uncut mudguard and seat, for an excellent price (less than £200).
The crankcases are due to picked up from Aerocoats (excellent service) which are near Beccles on Wednesday. I have just ordered tons of stuff from my local dealer (Orwells), Z Power and Debens, so hopefully I will be able to start rebuilding the engine this weekend.
I have just sat on the bike and the seat is quite wide, so hopefully it is more comfortable than the 1000 Katana I had.
The bike in the background is my 350 LC which is feeling sorry for itself at the moment as it feel over and broke the pro am fairing screen and brake lever
Thats all for now I will post some pictures of the engine parts when I pick them up.
Rob
Last edited by Robw on Mon Feb 23, 2009 7:20 pm, edited 1 time in total.
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
I thought it was about time for an update, as you can tell by the numerous queries I have had the project is moving on.
I got an engine from Jack (London Calling), I stripped it down to put the 1170 barrels on and paint it. As usual I got carried away and stripped it right down and sent the parts off to Aerocoats to get powder coated.
I had a couple of problems rebuilding, one being the selector position but with some photo's I took and help of the forum it is all together now. Another was some threads stripping in the crankcase and on the head, so after a lot cursing and careful cleaning all was well again.
I bribed a mate with homemade chocolate cake to help me fit the engine , we managed to get it in without damaging the powder coating, although my mate was suprised at heavy the engine was.
Here it is fitted, also I have fitted the Kerker and oil cooler.
I toyed with the idea of making a loom, but after looking at the original loom it looked in good condition, so I have fitted that. I have used heatshrink on all the surplus connections (indicators etc) to protect them from moisture and any earthing problems.
Today was a good day as I have successfully managed to wire the loom to the after market handle bar switch and spun the starter motor over and got the brake light working.
Here it is with the tank and seat unit just to remind me of what it will look like, once it is finished
The paint work will be going away in a couple of weeks to get done and tomorrow I will be ordering my Keihin carbs, so at the moment it is looking good for being on the road for July.
Cheers Rob
[/img]
I got an engine from Jack (London Calling), I stripped it down to put the 1170 barrels on and paint it. As usual I got carried away and stripped it right down and sent the parts off to Aerocoats to get powder coated.
I had a couple of problems rebuilding, one being the selector position but with some photo's I took and help of the forum it is all together now. Another was some threads stripping in the crankcase and on the head, so after a lot cursing and careful cleaning all was well again.
I bribed a mate with homemade chocolate cake to help me fit the engine , we managed to get it in without damaging the powder coating, although my mate was suprised at heavy the engine was.
Here it is fitted, also I have fitted the Kerker and oil cooler.
I toyed with the idea of making a loom, but after looking at the original loom it looked in good condition, so I have fitted that. I have used heatshrink on all the surplus connections (indicators etc) to protect them from moisture and any earthing problems.
Today was a good day as I have successfully managed to wire the loom to the after market handle bar switch and spun the starter motor over and got the brake light working.
Here it is with the tank and seat unit just to remind me of what it will look like, once it is finished
The paint work will be going away in a couple of weeks to get done and tomorrow I will be ordering my Keihin carbs, so at the moment it is looking good for being on the road for July.
Cheers Rob
[/img]
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
I am a very happy bunny, 
filled the new Kehin carbs up with petrol and it started first time. Not bad considering I hadn't built a Kwak engine before. I had to retighten the stator bolt as it came lose. But all is well now.
All I am waiting for now is the paint work, to come back from Hutch.
I will do some pictures later as the camera is on charge.
Rob
filled the new Kehin carbs up with petrol and it started first time. Not bad considering I hadn't built a Kwak engine before. I had to retighten the stator bolt as it came lose. But all is well now.
All I am waiting for now is the paint work, to come back from Hutch.
I will do some pictures later as the camera is on charge.
Rob
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
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Ginger Bear
- Hardcore
- Posts: 6850
- Joined: 16th Dec 2008
- Location: In the Dark.
- Contact:
-
Geoff Meager
- ZedHead
- Posts: 1140
- Joined: 5th Apr 2007
- Location: Dereham. Norfolk.
The camera is finally charged, so I have taken a couple of photo's of the engine with the carbs fitted and the clock brackets that I had made.
The funnel is my standby fuel tank, which shows that the carbs are drinking a large amount of fuel.
I am not to happy with the routing of the clutch cable, but I am limited by the position of the clocks and the exhaust, which has already melted some of the plastic cover, whilst I was busy on the other side of the bike.
[/img]
The funnel is my standby fuel tank, which shows that the carbs are drinking a large amount of fuel.
I am not to happy with the routing of the clutch cable, but I am limited by the position of the clocks and the exhaust, which has already melted some of the plastic cover, whilst I was busy on the other side of the bike.
[/img]
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
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martinz1000r
- Custard Cream
- Posts: 955
- Joined: 1st Jul 2007
- Location: Oxfordshire
Rob, looking really good especially given where you started from! Looks very much like you are going to beat me to the finish line as my Lawson is still languishing with it's engine half built.
Martin
Martin
Z1000R, Moto Martin, z900 A4 Crosby Replica, Harris Magnum 2, Suzuki GSXR 1100 Slabbie, Yamaha YZF750SP, SP1 Hoonda, Katana 1100, Bimota SB6R
Plastic must have melted - ram inside & set solid 
After having problems with the fuel tank being rotten, Hutch managed to get it welded and put the colour coat on the body work. The decals have'nt been fitted yet, just in case the tank still leaked. I put POR 15 in the tank and so far it has worked well.
The process of applying the POR 15 takes about 5 hours of constant shaking and draining, followed by 4 days so that it dries properly. My arms were aching for days.
The bike passed its MOT with only one hiccup, the rear brake starting leaking on the rolling road, Paul who did the test commented that the rear brake also felt a bit wooden.So, when I stripped it down I found that the powder coaters had left metal tape covering the drillings and when I had bled it, a small hole a popped the tape, so although it worked, there was no seal in the caliper.
The re test went well got a cracking rear brake now and I had a bit of extra endurance training when I had to push it about a mile when I ran out of petrol
I have just down a 30 miles on it in the glorious sunshine and all is well, I will give it a thorough check to see if anything has worked loose.
I would like to thank all the guys who have helped me with the building of the bike and to be honest it wouldn't have happened if it was not for the club
So what's next: defintely aim to show it at the Copdock show in October and hopefully get it to Stafford for the club stand, maybe an 8 plug head and gas flowing, also because of the big carbs the Pingel fuel tap doesn't fit, so I will be after another tank so that the boss for the tap can be re located. Does it ever end!!
The process of applying the POR 15 takes about 5 hours of constant shaking and draining, followed by 4 days so that it dries properly. My arms were aching for days.
The bike passed its MOT with only one hiccup, the rear brake starting leaking on the rolling road, Paul who did the test commented that the rear brake also felt a bit wooden.So, when I stripped it down I found that the powder coaters had left metal tape covering the drillings and when I had bled it, a small hole a popped the tape, so although it worked, there was no seal in the caliper.
The re test went well got a cracking rear brake now and I had a bit of extra endurance training when I had to push it about a mile when I ran out of petrol
I have just down a 30 miles on it in the glorious sunshine and all is well, I will give it a thorough check to see if anything has worked loose.
I would like to thank all the guys who have helped me with the building of the bike and to be honest it wouldn't have happened if it was not for the club
So what's next: defintely aim to show it at the Copdock show in October and hopefully get it to Stafford for the club stand, maybe an 8 plug head and gas flowing, also because of the big carbs the Pingel fuel tap doesn't fit, so I will be after another tank so that the boss for the tap can be re located. Does it ever end!!
Z1000R/ZRX, RD 125LC, Zx7r , Endurance racer
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