Double the troubleZZ. AMA style Racecrafters Z1000 (completed) and Moriwaki Z1R Turbo.

[zed1015]

Been working very sporadically on a couple of zed projects that will eventually emerge as a pair of AMA superbike style machines and now have made enough slow progress to make it worth starting a build thread.
This may/will take a while as I'm still needing lots of parts and i'm not in a hurry.
Both will be road going for daytime running and have the bare minimum needed to make them road legal with the emphasis on making them handle as well as go and stop.
The Z1R framed bike will be a turbocharged Gardner Moriwaki and the other 1000B framed with A bodywork will be normally aspirated with Kent cams and 8 plug head and is yet undecided for the paint but will be a period AMA colour scheme with Racecrafters livery currently favorite.
As in keeping with my previous builds these won't be sympathetic resto's so purists and those with a rivet counting disposition should look away now
Pic's to follow

[Swirl]

Oh eck wheres the pictures.

[chrisNI]

Pic's to follow

[zed1015]

The original plan was just to build a minimal carbed Moriwaki themed bike but that idea quickly grew into something bigger when I got the spare Rajay turbo from the Orient Express in payment for some work.
The other "bonus" bike is an unplanned consequence of having collected enough duplicate or unsuitable parts for the Moriwaki combined with other bits I had left over from other projects to build another rolling chassis so i thought i may as well make use of the surplus parts and do a dual build which will probably take three times as long.

Parts in the pile so far are..

A Z1R frame with rotten shock mounts, a bare 1000B frame with no brackets, shock mounts or rear loop on it. Z1R and 1000a fuel tanks, a pair of Yam XJR swingers, MK2 and 1000A tails, a zx7r front end, a pair of zx12r wheels, zx9r rear wheel, a pair of Yam FJR1300 forks with two bottom yokes , a rusty 2/4 seat base and a couple of bottom ends.
There's a possibility I may be able to do something with that ???

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[zed1015]

In the parts stash so far for the Z1R there's the spare rebuilt and balanced Rajay turbo from the Orient express drag bike, a Wastegate ( but no exhaust to join it all together as yet ), ATP plenum, Super B carb that I first had on the Drouin, GPZ1100 Unitrack cams, Ape 32t slotted cam sprockets ,MTC lockup clutch, Barnett extra plate clutch pack, Titanium valve spring retainers, HD cylinder studs, bronze guides and the remains of a Bill Hahn Boost retard distributer ignition that's missing the cover, GM hei module, belt, crank pulley and coil.

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And here a fresh welded MK2 crank (by Roger Upperton), assorted APE nuts, case studs, top idler bracket, needle clutch pusher etc, a Deep sump with Turbomaxx billet 40% extra flow oil pump and a freshly bored 1075cc block with 10.25 comp Wiseco pistons.
The head will be either a J or GPZ1100 Unitrack who's larger 40cc combustion chambers will drop the comp down to a turbo friendly 8 to 1.

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For the "B" based bike which will have "A" bodywork there's another fresh 1075cc block with 12 to 1 comp Wiseco's ( again dropping to around 10 -1 with a 'J' head ), a set of fast road Kent cams 'w' slotted sprockets , Ti retainers, HD valve springs, my own billet idler wheels, HD cam chain etc and two pairs of 1.5 ohm dyna coils and Dyna S' ignition for the 8 plug head.

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Also got a very nice welded 900 crank.

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And the J head i twin plugged that was originally on the Drouin.

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[zed1015]

First job on the long list is to get the Yamaha XJR1300 swingarms in.
The original Zed spindle and pivot hole should ideally be 16mm but in actual fact the hole is 16.2mm and the spindle is 15.8mm so a massive 0.4mm slack fit that translates to much more at the rear wheel end which doesn't do the bikes handling much good.
The idea is to tighten all the clearances in the running gear, engine mounts and brace the frames to eliminate as much flex as possible especially for the turbo bikes 200hp + potential.
The XJR s/a spindle is 20mm and rather than sleeve the arms bearing tube down to fit the original zed spindle and still have the play there's just enough meat on the zeds frame pivot to go out to this, so a line boring tool was made for the job.

This consists of a length of ground bar and a 20mm rotabroach cutter.


The end of the bar turned down to be a tight snug fit inside the cutter.

And the end tapped M6 to secure the cutter and a drill arbour made to drive it from the battery drill.

Then with some cutting fluid, work evenly from both sides

And job done.

Spindle slips in with a slight drag, zero play and no room for paint..

But not quite finished yet..

[Taffus]

Awesome Rob, just Awesome!

[weaver]

enjoying this one

[Ginger Bear]

Rob, Once again, this looks like it will be a very informative & interesting thread.

I will follow it with avid interest.

[Swirl]

Nice that is something I have been interested in for the braced and raced Z1-R after reading about the play in the pivot sometime ago

[Swirl]

Looks great

[zed1015]

The next job is to eliminate any lateral movement of the swingarm at the pivot.
This is something often overlooked when fitting modern arms which then still allows the arm to float against the thin flexible steel end caps especially when cornering.

The caps need a larger support area to at least the inner diameter of the arms pivot tube so a steel disc was machined with a light press fit on the frame boss.

And then Bronze welded on.

The disc sits very slightly proud of the frame boss and once done i very lightly spot face the support area with my home made in line cutter to true up the face and ensure that everything is square, parallel and level with the original boss and that the internal width is unchanged

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An alternative to this when not modifying the frame is to either make some beefier end caps or insert some 3mm minimum thick shims in the original caps and trim the arms pivot width to compensate.

[Pigford]

Amazing as usual Rob !

[Philippe]

Looks like the man knows what's needed to make an altered bike ride safely!
Nice work, following with interest.
GrtZ
Philippe

[zed1015]

Now need to get the swingarms in.
First I have to fit and center the rear wheels in relation to the shock mounts on the arms so I can then find the center of the s/a pivot in relation to the wheels but both the ZX7 and ZX12 wheels have different spindle sizes to the XJR slots and there's no bearings available to simply drop in the wheels to take the XJR spindle size so i have to modify some adjuster blocks to make up the differences.

So turn up some stepped sleeves to press into to the blocks

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The outer face of the blocks were recessed to take the wider step of the sleeve then skimmed flush.

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Block for the ZX12 spindle

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Block for the ZX7 spindle

Ready for the wheel