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Project Racer

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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Zomerset Zed
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Project Racer

#1 PostAuthor: Zomerset Zed » Tue Oct 04, 2016 6:11 pm

I have just purchased this lovely thing:

Image

Image

Image

Not very good photos im afraid but it was a dark night in a barn in deepest Somerset :wink:

As many of you will know its an ex. Phase 1 (my neighbors) P&M framed Z1170 hybrid motor endurance race bike :P

General spec. is:

Frame 142, last frame they built, not been used, just been painted.
Freshly rebuilt 1170 Graham Salter with GPZ worked on head, Big valves, Wiseco pistons, welded crank, undercut gearbox.
Classic ally Dymags
Brembo discs
AP calipers
Steel fabricated P&M yokes
Marzochi forks
Falcon shocks

Also comes with:
Ally endurance tank 17l
Harris full fairing
Stainless 4:1 and reverse megaphone
Keihin CR carbs and bellmouths
Krober tacho

Needs:
Ignition system
Ignitor housing
LH side gen engine case (fabricated/machined)
Gear linkage
Clutch actuator and perch/cable etc.
Rear brake master cylinder/bracket hoses etc.
Oil cooler and hoses and engine connections/brackets etc.
Fairing brackets
seat unit
Chain and sprox
Front mudguard
Paint
Lots of odds n sods!

Heres a pic of its sister :D

Image
Spot the "mistake" :?:

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zed1015
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Re: Project Racer

#2 PostAuthor: zed1015 » Tue Oct 04, 2016 6:25 pm

Zomerset Zed wrote:
Heres a pic of its sister :D

Image
Spot the "mistake" :?:


Obviously a Suzuki with delusions of grandeur.

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Al
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#3 PostAuthor: Al » Wed Oct 05, 2016 9:50 pm

Vary nice indeed.
AL
1981 J1

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Zomerset Zed
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#4 PostAuthor: Zomerset Zed » Thu Oct 06, 2016 9:03 am

Obviously a Suzuki with delusions of grandeur.


Very good :wink:

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#5 PostAuthor: HowieD » Fri Oct 07, 2016 4:55 am

Envious doesn't cover it !
CD185, Maggot, Z1-R, Horace

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#6 PostAuthor: martinz1000r » Fri Oct 07, 2016 9:08 am

Will we see you at Spa and Donnington next year with the other track focused Z's?
Z1000R, Moto Martin GPz, z900 A4 Crosby Replica, Harris Magnum 2, Suzuki GSXR 1100 Slabbie, SP1 Hoonda, Katana 1100, Bimota SB6R and Tuatara, Ducati 999

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#7 PostAuthor: Zomerset Zed » Fri Oct 07, 2016 12:06 pm

Will we see you at Spa and Donnington next year with the other track focused Z's?


It is the intention to take it initially short circuit racing, then may be endurance if i can get a good enough team together. Already have a good mechanic and another good rider. I have a lot to do as i tend to work on large engineering contracts through the dark months, maybe away from home etc. which makes it difficult to work on the bikes.

I think for next year i will be doing some racing and track-days and maybe some of the Belgian classic events like Chimay, Geddine etc. as i love the relaxed nature of those races :shock:

I need to find some more room for bikes first :roll:

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#8 PostAuthor: Zomerset Zed » Fri Oct 07, 2016 12:07 pm

Envious doesn't cover it !


But you have Horace :!:

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Re: Project Racer

#9 PostAuthor: Gus » Fri Oct 07, 2016 12:35 pm

Zomerset Zed wrote:
Image
Spot the "mistake" :?:


I've been down to Phase 1 and used to mechanic for Team Glam Racing against Russel and the boys.

Peter is as hard as a rock and would wring the neck of their P&M's usually to podium places.

He was or still is a fighter pilot I believe.

Myth, story or truth has it that he "borrowed" a fighter one day and went and "buzzed" the start finish straight at one of the tracks he was racing at.

Cheers

Gus
"Set the GRINDER on it"

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#10 PostAuthor: tlc » Fri Oct 07, 2016 3:19 pm

Zomerset Zed wrote:if i can get a good enough team together.


You'll need someone to tell you which parts are not standard.

I'm your man - if you have a parts book that is.
Asphalt Cowboy Z1100R, 1981 Z1000J

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Zomerset Zed
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Time to start on this one

#11 PostAuthor: Zomerset Zed » Fri Dec 01, 2017 6:17 pm

Its made it into the shed:

IMG_20171128_180442.jpg


Its feckin cold out there :cold

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Re: Project Racer

#12 PostAuthor: KWACKERZ1 » Sat Dec 02, 2017 12:30 pm

Very nice !!!

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Small progress

#13 PostAuthor: Zomerset Zed » Mon Jan 29, 2018 6:43 pm

I started a few jobs on the P&M:

Exhaust studs and QD flanges:

I used some left over M8 studs i had from the Zed project and had Mikey plate them for good measure. Did a quick CAD model of the ports geometry so i can get stud length and the design of the 2 part QD flange right:

IMG_20180112_153416.jpg


Exhaust flange section.jpg


It worked out that i should be fine leaving 30mm of stud proud of the head. I have a mixture of 2 different types of stud with differing thread length each end, so i wanted to work out if i could use both types. Works out i can.

So i got the parts made up:

IMG_20180129_140926.jpg


IMG_20180129_140944.jpg


And offered them up to the headers:

IMG_20180129_141510.jpg


IMG_20180129_141526.jpg


I will match the pipes to the spigots with a die grinder and sanding wheel later. I had to cut down 3 of the headers by 3.5 to 8.5 mm to get them all in line so they all seat in the spigots in line. This is important for a good seal and also for gas flow at high rpm :D


IMG_20180129_140545.jpg


On the head:

IMG_20180129_134707.jpg


Working out which of the 3 springs per header i am going to use:

IMG_20180129_140207.jpg


End can loosely in place:

IMG_20180129_134746.jpg

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Re: Project Racer

#14 PostAuthor: GPZ592 » Mon Feb 19, 2018 9:23 pm

I do love a nice P&M :)

Those QD headers are simply gorgeous. Looking forward to more updates on this project :up
"Racing is life. Anything before or after is just waiting" - Steve McQueen

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Zomerset Zed
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Brackets, brackets.....

#15 PostAuthor: Zomerset Zed » Wed Feb 21, 2018 7:24 pm

The bike was missing a rear brake cylinder and its bracket, so i got an R1 cylinder off ebay for £20 (like new) and started with cardboard, then progressed to 8mm ally plate. I chose 8mm because i wanted to have the bracket support the mega off its front mounting and this was the thickness between the frame lugs and the bracket on the Mega when offered up in a near position. First to cut it out:

IMG_20180204_161738.jpg


Kinda fits but the brake lever QD pin fowls the button head M8 holding the mega on and the angle of the cylinder is too shallow and too far away from the diagonal frame rail for a super smooth and linear operation, so more cutting/drilling required. I have 2 sets of mounting holes on the bracket for the cylinder so i have a huge range of adjustment for the lever height which is difficult to get right without being on my knee trying to modulate the rear.

IMG_20180204_162611.jpg


I knew there was a reason i usually design things on CAD, but i'm going back to "proper" engineering techniques (takes longer, but i am outside in the sun)

Also decided to make a secondary mega bracket out of 30 x 5 ally bar:

IMG_20180217_154355.jpg


Using the old G-clamp and block of ally method in the vice to create a joggle to clear the top of the rear shock

IMG_20180217_155305.jpg


IMG_20180217_162128.jpg


Also made up an ally spacer to move the bracket out by 10mm:

IMG_20180217_165202.jpg


All done :D

IMG_20180218_155645.jpg
IMG_20180218_155653.jpg
IMG_20180218_161621.jpg
IMG_20180218_161629.jpg


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