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Z1B Restoration

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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Philippe
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Z1B Restoration

#1 PostAuthor: Philippe » Fri Jul 27, 2018 4:32 pm

Hi guys
some of you will remember that I bought a wreck of a Z1B at the end of januari this year.
The past months I was involved in the restoration of a KZ1000Police and this project is nearly finished.
In the mean time I started today a new project, the restoration of my Z1B.
I invite you all to join me on the long way from start to finish.
For those who haven't seen the pictures of the wreck I bought here are a few.
DSCN3329.JPG
at the beginning there was a wreck


as you can see there will be a lot of work to do but nothing I can't handle

DSCN3194.JPG
a broken cooling fin, as usual


I have a few Z900 cylinderheads which are complete, so if this one can't be saved, I 'll take a spare one

DSCN3195.JPG
at the butchers...


As you can see the rear mudguard was chopped off, it was far beyond the point of repair anyway, it was really rotten.

DSCN3337.JPG
no comment...


completely rotten but there were still a few square inches of chrome...

DSCN3330.JPG
Help, I need a replacement...


A new front mudguard is needed, this one is allso beyond repair.

DSCN3331.JPG
where are the clip-ons ?


In the past someone cut the lampholders to put clip-ons on ...

DSCN3338.JPG
strange place to keep a spare tube


As you can see, the tank rubbers were gone and the previous owner used an old inner tube to dampen the fuel tank, it's a strange world isn't it ?

DSCN3340.JPG
after a few hours...


So this is the actual situation, perhaps more pictures of my new discoveries tomorrow.
Greetings from Belgium
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

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hartyb
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Re: Z1B Restoration

#2 PostAuthor: hartyb » Fri Jul 27, 2018 5:12 pm

thats going to be a good project
Z1000 Z1000A1, Z1000ST, KZ1000p, Z1000Mk2 which I am collecting parts for.
Z1R ready for paint, Z900A4 running,
Z1300 1979
GPZ1100 Unitrack, 3x GPZ 750Turbo,
ZZR1100 Purple and orange
along with some lesser makes :eek

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Pigford
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Re: Z1B Restoration

#3 PostAuthor: Pigford » Fri Jul 27, 2018 5:15 pm

Watching with interest - keep the good work & photo's coming!!!
And on the 7th day... Zeds were created!

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ADRIAN H
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Re: Z1B Restoration

#4 PostAuthor: ADRIAN H » Fri Jul 27, 2018 7:15 pm

Will watch with interest. Plenty of scope for improvement.
👀 👀 👀
email - adrianhorsfield@live.co.uk

deka
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Re: Z1B Restoration

#5 PostAuthor: deka » Fri Jul 27, 2018 8:17 pm

Wow phillipe you amaze me again if anyone can do it you can
kz900 c
bmwr1200gsa
955i daytona

Philippe
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Re: Z1B Restoration

#6 PostAuthor: Philippe » Fri Jul 27, 2018 8:53 pm

Hi Derek

you won't believe it, it did worse than that...
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

Philippe
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Re: Z1B Restoration

#7 PostAuthor: Philippe » Sat Jul 28, 2018 4:37 pm

Hi Guys

continued the "demolition" on the Z1B today
Here are some more pics, enjoy them
DSCN3343.JPG
before


I stripped allmost everything from the frame to take the engine out.
I allso dismounted the camshafts to get a bit more clearance between the engine and the frame and I laid it down on its right hand side.

A few minutes later this was the result
DSCN3344.JPG
after


I'll disassemble the engine later this week to see what is inside
In the mean time I tried to create a bit of order in the chaos after the disassembly and stored several parts in boxes to make an inventory of what I have and what is missing.
I allso collected several parts to use from my stockpile and this is the result
DSCN3347.JPG


All these and a lot more will become a Z1B. When will it be finished ?...I don't know, time will tell.
Greetings from Belgium
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

deka
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Re: Z1B Restoration

#8 PostAuthor: deka » Sun Jul 29, 2018 8:38 am

Top work especially engine removal
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bmwr1200gsa
955i daytona

Philippe
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Re: Z1B Restoration

#9 PostAuthor: Philippe » Wed Aug 01, 2018 3:49 pm

Hi guys

did some work during the past few days, on the engine and on the frame.
I'll start with the engine:
It was taken apart completely, first the head came off then all the remaining engine covers and finally the cylinderbank.
After that I removed the pistons and then it was time to split the cranckcase.
All the inner parts were putted in boxes, to keep them "clean" and to avoid them to become rusty from the moisture in the air...
At the end of the day I started to degrease the upper cranckcase.
DSCN3365.JPG

I use thinner to degrease it, and I do that outside, if not I become "high" from the vapours of the thinner...
That was yesterday.

Today I decided to give a bit of attention to the frame.
There were parts and nuts added, holes made where there aren't supposed to be, parts grinded off and one "ear" on the left hand side was twisted and deformed.
DSCN3371.JPG

DSCN3372.JPG

DSCN3373.JPG

SET THE GRINDER ON IT
DSCN3374.JPG

The result of 10 minutes grinding
After that job it was time to clean up the frame

Another 30 minutes of work gave these results
DSCN3376.JPG

DSCN3377.JPG

DSCN3375.JPG


There were a few holes in the frametubes where there aren't supposed to be so they had to be closed
DSCN3384.JPG

I used an old damaged bolt to screw in the hole, the bolt is an M10x1,25 and was used to secure the engine in the frame. Someone used an M10x1,5 nut and damaged the thread. I couldn't repare the thread so I used the bolt for filling op the hole. Never throw anything away, you might need it someday!

The tools I use are simple : see for yourself.
DSCN3378.JPG

That's really all it takes and a bit of work and patience.
The next part will be the repair of the "ear" at the back left hand side.
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

Philippe
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Re: Z1B Restoration

#10 PostAuthor: Philippe » Wed Aug 01, 2018 4:15 pm

I'm back and the story continues...
The "ear" at the left hand side was deformed. I think someone in the past crashed the bike causing the damage.
It's important that the"ear" is rather straight in order to position the indicator in a decent way.
DSCN3382.JPG

The indicator rubber was trapped between the inner and the outer metal part and it was neccesary to remove it before I could heat the metal.
After a bit of hammering the metal gave way and the remains of the indictor rubber were removed. Now it was time
to heat the metal in order to get it straight and more or less into the correct shape
After heating and hammering a few hours I was pleased with the results, see for yourself
DSCN3390.JPG

DSCN3389.JPG

Once again simple tools and a gastorch, not a sophisticated one, no just keep it simple
DSCN3380.JPG


The swing arm allso caused a bit of a problem...the two bolts of the small parts at the end were both rusted solid with the swing arm and snapped off.
DSCN3366.JPG

I decided to cut the small steel parts in half, remove one part and then I could remove the other half to expose the remains of the bolt.
DSCN3369.JPG

After that it was a matter of WD40, a bit of time and a pair of pliers
DSCN3370.JPG

So far, so good.
Oh, I forget to say that I have a spare pare of those little parts to put in the swing arm...the ones I removed can't be reused.
I chose that drastic way in order to avoid damage to the tread in the swingarm.
Tomorrow more news about the repairs on the frame, the making and welding of the missing parts...
To be continued...
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

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chrisNI
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Re: Z1B Restoration

#11 PostAuthor: chrisNI » Wed Aug 01, 2018 4:44 pm

Good work Philippe you’re steaming ahead..
:D

deka
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Re: Z1B Restoration

#12 PostAuthor: deka » Wed Aug 01, 2018 7:43 pm

Top work philippe
kz900 c
bmwr1200gsa
955i daytona

DavidZ1R
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Re: Z1B Restoration

#13 PostAuthor: DavidZ1R » Wed Aug 01, 2018 7:46 pm

Keep the pics coming Philippe, great job, love it.
CB125 GT380 CB750F1 Z1R GPZ 750 Turbo Z1R

Philippe
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Re: Z1B Restoration

#14 PostAuthor: Philippe » Sat Aug 04, 2018 4:25 am

Hi guys
a few days later than I promised but here's the next episode;
As you noticed there were parts of the frame missing : at the right hand side someone cutted off the holder for the rubber dampers of the exhaust. Not a nice sight ...
DSCN3373.JPG
oops there's something missing...

On the left hand side they allso decided that the "tube" of the seat lock was in the way of the home made locking device so it was removed...
DSCN3387.JPG
who needs a seat lock anyway?

Since I'm not that good in bending and shaping metal I used steel tubes to fabricate the missing parts ...
DSCN3386.JPG

I only had to weld those on the frame, I never had any technical education but learned it all by trial and error and now, after many years, I succeed in welding two metal parts together ...
DSCN3393.JPG
the tube for the seat lock mechanism

Allmost ready, it just needs a slot to get the mechanism in and the mechanism itself, but that's a detail...
Originally it was made of a steel plate which was bend . A Z1 owner can see it for himself, at the underside of it you can notice the seam. I had to use a piece of steel tubing with holes drilled in and smoothed edges.
I took an M6 bolt to secure it into place before welding it on the frame.
DSCN3394.JPG
the part for the exhaust rubbers

The missing part consists of two pieces, one to elongate the frame tube and another to recieve the rubber dampers.
I welded the frame tube first so I could clean up the weld without risking damage to the damper holder.
This will do the job!
Just notice that I even succeed in reproducing the "splatter" that was common on the frames of that era :blush
Next time some work on the cleaning of the engine parts.
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

Philippe
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Re: Z1B Restoration

#15 PostAuthor: Philippe » Sun Aug 19, 2018 4:03 pm

Hi guys
as promised some pictures of the engine cleaning.
I allready posted a picture of the upper cranckcase...
DSCN3365.JPG
before the cleaning...

I did some work on it and it looks quite clean now. See for yourself...
DSCN3420.JPG
the upper cranckcase

No sandblasting, only rotating nylon brushes and a lot of elbow grease.
The studs are cleaned, degreased and painted with heat resistant paint. Not the two on each side because these get in the oil channel, no paint on those!
The other engine parts will get the same treatment.
During the disassembly of the engine I discovered some nice and some bad surprises, as usual...
DSCN3353.JPG
a nice surprise

The original metal plate was still there. Most of the time these are gone.
As a bonus I found out that the two little chromed bolts that keep the chrome cover of the starter motor in place, were used to bolt the plate to the sprocket cover.
DSCN3354.JPG
the two little bolts

There was allso a nasty surprise ...
Sometime in the past the oil drain bolt must have been stuck in the sump, someone banged on it with a hammer to loosen it but that resulted in a crack in the sump.
They had to dismount the oil sump and weld the crack in order to use it again.
DSCN3360.JPG
the welded oil sump

DSCN3361.JPG
the evidence...

You can see the place where they've put the chisel, it not only took a bit out of the oil sump but it allso made a crack in it.
I have some spare parts so I'll use another oil sump and replace the welded one.
When disassembling the engine I found out that the pistons were rather clean. Mostly there's a thick layer of soot on them, not difficult to remove but sometimes it gives an indication of the state of the valve oil seals and of the wear of the valves and valve guides.
DSCN3357.JPG
a look into the hart...

DSCN3356.JPG
the valves

Anyway, I allways replace the oil seals and clean the valves when I reassemble an engine. The valves are allways checked to see if they're not bend and grinded in the valve seats to assure a good fitting and sealing.
When the valve guides are worn out, they're replaced with new ones. That's done by a professional! I don't have the tools or the equipment...or the skills to do it.
Since I'm back to work things will take a bit longer.
Next time some more news of the preparation of the frame prior to painting.
Tada
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!


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