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Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

Work in Progress

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zed1015
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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#106 PostAuthor: zed1015 » Tue Sep 07, 2021 2:14 pm

With the 28 additional bits of bracing welded in it's time to get the last few fiddly jobs out of the way starting with some threaded mounts
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To take a one piece alloy mudguard ( Recycled road signs to the rescue again :D )
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Some bracketry hung off the original tail mount stops the end of the mudguard and tail light flapping about.
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And a Hodna blackbird rear light the same as i used on the Drouin fits the bill and looks like it's meant to be there.
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With the rear light bolted on you can't get to the two concealed tail mount bolts ( and vice versa) so machined up a couple of snug fitting tapered stainless pegs which screw in place of the original bolts
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And the tail simply pushes on to them and is secured by the two bolts at the front under the seat in a similar way the later Z1R etc tails attach..
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While i was at it i also made a couple of stainless coil adaptor brackets that bolt to the frame and allow the further most Dyna coil mounting holes to be used
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Which give plenty of clearance for the terminals and no risk of shorting
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Last edited by zed1015 on Wed Sep 08, 2021 12:27 pm, edited 6 times in total.

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zed1015
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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#107 PostAuthor: zed1015 » Tue Sep 07, 2021 2:31 pm

And this is where we are as of today.
Just battery and electrical mounts to figure out under the seat hump, finish the exhaust and a couple of small brackets and it's ready for the build proper.


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Bill P
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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#108 PostAuthor: Bill P » Tue Sep 07, 2021 5:00 pm

Great reading as usual , Hope the knee's goin on ok to :)

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#109 PostAuthor: zed1015 » Mon Sep 13, 2021 9:57 am

Next big item on the list is the exhaust so gathered the raw materials to make the link from the Exhaustcraft headers to a silencer.
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For the price, this very nice merge collector was cheaper ready made than the materials and effort to make my own.
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The only fly in the ointment is that the slip joints were 2mm wider dia than claimed so some jiggery pokery is required to tighten up the fit for the headers and keep the gasses from escaping.
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First thought was to cough up for a set of these exhaust expanders but the cheap ones are notorious for breaking the segments and decent ones require more outlay than a ready made exhaust system which sort of defeats the object.
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So time for another cunning plan i think :wink:
Last edited by zed1015 on Tue Sep 14, 2021 7:00 am, edited 6 times in total.

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#110 PostAuthor: zed1015 » Mon Sep 13, 2021 10:50 am

After a bit of a dig about in the scrap bin i come up with this little lot.
An off cut of mild steel bar, a 20mm Yamaha R6 front wheel spindle, a 20mm id swingarm bearing pivot tube and some 6mm steel plate.

Due to the previously mentioned technical glitch of my PC eating all the detailed pics there's no images of the actual fabrication so some imagination needed.
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.
The chunk of steel bar was turned to the required size, bored out 25mm , a 10 degree internal taper turned into each end, a couple of grooves cut for the 'O' rings and then the whole thing was carefully freehand cut into six sections with the angle grinder, de-burred and numbered to keep them in order of appearance .
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Then assembled with the 'O' rings to hold them together
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The 20mm R6 spindle got a matching 10 degree external taper turned on the head end and an m6 threaded bolt tapped midway.
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Then finally a section of bearing tube received another 10 degree external taper, a slot for the R6 spindles 6mm bolt and was then welded to a section of the 6mm plate so it can be securely held in the vice.
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Then slot the whole lot together
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In the vice ready for testing. Bolt in the slot allows full travel of the R6 spindle drawbar but prevents it and the pipe to be expanded from rotating when tightening the spindle bolt .
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Fingers crossed this actually works and a days graft isn't wasted.
Last edited by zed1015 on Tue Sep 14, 2021 7:08 am, edited 7 times in total.

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#111 PostAuthor: zed1015 » Mon Sep 13, 2021 11:33 am

Fortunately i'd had Dave at Exhaust craft leave the headers long so that i could cut them to my own length which means i have some sacrificial offcuts to use a guinea pigs without risking damaging the actual pipes.
So with everything lubed up and a few turns with the aid of a long breaker bar it actually bloody worked :hoo

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And made a very neat snug fitting job.
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So bit the bullet and proceeded to the actual pipes which went without issue.
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Very happy with the results and glad i didn't just waste valuable funds on some of those hand held pipe expanders which i'm sure you couldn't get the required force on them without having to also grip and risk damaging or marking the actual exhaust. .
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Now to get on with the next stage and make the link pipe and can.
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Last edited by zed1015 on Mon Sep 13, 2021 7:49 pm, edited 3 times in total.

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#112 PostAuthor: zed1015 » Mon Sep 13, 2021 1:42 pm

And talking of the end can, here's a Kerker i aquired from a club member.
The one or two minor dents and scrapes from the original strap mount etc have disappeared along with just over a third of it's length to improve the propotions.
The original mild steel baffle in the middle will be replaced by the stainless one at the bottom.
The original baffle contained a lot of dead space so even though the can is much shorter it will actually be no louder and possibly slightly quieter than the original due to more working baffle length.

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And once the exhaust is complete i've got this scarce little trinket stashed away to finish it off.
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Original style genuine NOS embossed badge will look much better and in keeping with the era than the later Supertrapp version.
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Just need to get it positioned on the bike and i'll be able to connect the system together.

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#113 PostAuthor: 750 R1 » Tue Sep 14, 2021 8:16 am

Good to see you back at it Rob....!

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#114 PostAuthor: zed1015 » Tue Sep 14, 2021 12:03 pm

Bill P wrote:Great reading as usual , Hope the knee's goin on ok too :)

Thanks.
The knee's going great.
Don't even notice it most of the time now, especially since i've now got shut of more than the near 3 stone i piled on in 2020 whilst waiting for the op.

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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#115 PostAuthor: zed1015 » Wed Sep 15, 2021 11:14 am

Another little job off the list this morning in preparation for mounting the exhaust.

Drilled a couple of 10mm holes at 80mm centers in the frame

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Then turned up a couple of 12mm OD m8 internally threaded stubs with the ends reduced for a tight fit in the frame.
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Which were jigged onto a flat plate to keep them square in relation to each other whilst welding.
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Job done and now to mock up a hanger to get the end can in the best position.
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Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.

#116 PostAuthor: 750 R1 » Thu Sep 16, 2021 6:28 am

Nice work on the pipe expander, a great example of, "Necessity is the mother of invention"...


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