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Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Moderators: paul doran, Taffus, KeithZ1R, chrisu
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Z1streetfighter71
- Custard Cream
- Posts: 628
- Joined: 16th Oct 2020
- Location: Galway-Eire
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
She is starting to look like one mean ass bike.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Good work and really well thought out!
Keep the updates coming!
Keep the updates coming!
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Racecrafters dry build is complete and i've now found a local custom trimmer who says they can re-upholster and cover the seat how i want once the pan is ready so went ahead and pulled it all apart on Sunday.
As well as getting the seat base fit for service i decided i may as well get the rest of the parts done too that needed it so took the wheels ,rear mudguard, clock mount and a few other odds and ends over to the powder coaters yesterday for a coat of satin black.
When i dropped them off i was told they are very busy and the job will take 10 to 14 days so not wanting a further delay i got up and out early this morning and pushed to finish the frame, sweating any rust traps with fillets of bronze and gave it a final going over ready for another trip to the coaters in the morning along with the side stand and rear motor mount to be done in Gloss black..
As well as getting the seat base fit for service i decided i may as well get the rest of the parts done too that needed it so took the wheels ,rear mudguard, clock mount and a few other odds and ends over to the powder coaters yesterday for a coat of satin black.
When i dropped them off i was told they are very busy and the job will take 10 to 14 days so not wanting a further delay i got up and out early this morning and pushed to finish the frame, sweating any rust traps with fillets of bronze and gave it a final going over ready for another trip to the coaters in the morning along with the side stand and rear motor mount to be done in Gloss black..
Last edited by zed1015 on Mon Aug 21, 2023 4:14 pm, edited 5 times in total.
-
Z1streetfighter71
- Custard Cream
- Posts: 628
- Joined: 16th Oct 2020
- Location: Galway-Eire
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
That is one solid frame 
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Pile of new parts on the bench growing daily in anticipation of the call to say the powder coated parts are ready.
New tyres , discs, wheel bearings and seals, swingarm bearings, fork bushes and seals,brake pads, steering bearings, newton aero filler, spark plugs. including a lucky Ebay find of a batch of NOS NGK C9H 10mm short reach for the additional holes in the eight plug head and an Electrex race alt that allows the use of the starter motor which unbelievably they are still selling with the unresolved fault that short circuits the oil from the main oil gallery straight back to the sump and starves the cams..
Unfortunately the alt is only available to fit the later mk2 onwards big taper cranks and as i'm going to run a welded small taper Z9 item i'll have to devise a cunning plan to sort that out
New tyres , discs, wheel bearings and seals, swingarm bearings, fork bushes and seals,brake pads, steering bearings, newton aero filler, spark plugs. including a lucky Ebay find of a batch of NOS NGK C9H 10mm short reach for the additional holes in the eight plug head and an Electrex race alt that allows the use of the starter motor which unbelievably they are still selling with the unresolved fault that short circuits the oil from the main oil gallery straight back to the sump and starves the cams..
Unfortunately the alt is only available to fit the later mk2 onwards big taper cranks and as i'm going to run a welded small taper Z9 item i'll have to devise a cunning plan to sort that out
- PICT0395.JPG (313.59 KiB) Viewed 109341 times
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
A bit of a setback ! 
Spent the last day or so prepping the crankcases and plugging the barrel oil feeds etc ready for building up the bottom end and dropping in the frame when it returns
Gave them a good de-grease and pressure wash before a session in the blast cabinet ready for paint then something caught my eye as i was just finishing the last piece.
The dust from blasting revealed a barely visible fracture in the needle bearing saddle for the opposite end of the output shaft in the upper case as it became stained from oil residue trapped within.
I've had to highlight it with a fine line marker so it shows in the pic otherwise it's almost invisible
These are spare cases left over from the Orient Express Drag build that i took in part payment so have seen some action and the fracture can't spread because it ends at a through hole in the casting.
It looks like the usual result of not getting the hole in the bearing lined up and the dowel was pressed into the case although the dowel is also missing
Going by the paired case stamp they are possibly the original cases from when the Drag bike was first built in the US unless it was done by Steve Tong.
It's unlikely to cause any problems but i can't live with it for this build so i'm now looking for some more cases and i've stuck an ad in the wanted section.
Any pre MK2 cases will do as long as they are usable and have their matching main bearing cap.
Not bothered about year, model, dodgy or missing engine numbers or a few stripped threads as long as they are usable and of course as cheap as possible.
Can possibly offer parts in trade or even a suitable amount of plungers repairs if required.
Spent the last day or so prepping the crankcases and plugging the barrel oil feeds etc ready for building up the bottom end and dropping in the frame when it returns
- PICT0414.JPG (164.62 KiB) Viewed 109245 times
Gave them a good de-grease and pressure wash before a session in the blast cabinet ready for paint then something caught my eye as i was just finishing the last piece.
- PICT0406.JPG (251.78 KiB) Viewed 109245 times
The dust from blasting revealed a barely visible fracture in the needle bearing saddle for the opposite end of the output shaft in the upper case as it became stained from oil residue trapped within.
I've had to highlight it with a fine line marker so it shows in the pic otherwise it's almost invisible
These are spare cases left over from the Orient Express Drag build that i took in part payment so have seen some action and the fracture can't spread because it ends at a through hole in the casting.
It looks like the usual result of not getting the hole in the bearing lined up and the dowel was pressed into the case although the dowel is also missing
- PICT0410.JPG (146.25 KiB) Viewed 109245 times
Going by the paired case stamp they are possibly the original cases from when the Drag bike was first built in the US unless it was done by Steve Tong.
- PICT0418.JPG (155.11 KiB) Viewed 109245 times
It's unlikely to cause any problems but i can't live with it for this build so i'm now looking for some more cases and i've stuck an ad in the wanted section.
Any pre MK2 cases will do as long as they are usable and have their matching main bearing cap.
Not bothered about year, model, dodgy or missing engine numbers or a few stripped threads as long as they are usable and of course as cheap as possible.
Can possibly offer parts in trade or even a suitable amount of plungers repairs if required.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Could that case not be repaired? Had the same issue with my case and had the crack ground out, filled with weld and then machined back to standard.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Bevelhead wrote:Could that case not be repaired? Had the same issue with my case and had the crack ground out, filled with weld and then machined back to standard.
Yes! It could easily be welded which i may do at a later date if i build something else.
The case will probably be just fine as it is to be honest and i know it was used like this because it's the cases from the engine that was last run in the drag bike when it blew the top end in 82. ..
The crack can't spread because it ends at the casting hole and it's flanked by case bolts and you can't even see it without the maker pen which makes it look a hundred times worse than it is.
These cases have been bored out to take bigger liner spigots and i'd rather have the increased base gasket sealing area of a stock set anyway.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Finally got the frame back from Scunthorpe powder coaters.
I actually picked eveything up on Friday but when i got it all home and unwrapped the frame i was gobsmacked to discover that they had masked off the frame number and left that area bare metal.
I didn't ask for this so took it back yesterday (Wed) to get re done along with a couple of other small parts i wasn't happy with and then got an unexpected surprise call this morning to say it was all ready to pick up.
It's the first time i've used them and apart from that minor setback i'm very impressed with the quality and service so far
Speedo mount, rear caliper hanger, coil mounts and front mudguard mounts in satin
As are the seat base, battery box, back mudguard and mounts.
Fitted the new tyres to the satin wheels over the weekend along with new bearing and seals .
And built the rear mudguard assembly
Which is now in position courtesy of some ally cup washers and countersunk stainless screws after going round the frame and chasing all the threads.
Not much more i can hang on the frame until i find some crankcases to build the bottom end to drop in.
I actually picked eveything up on Friday but when i got it all home and unwrapped the frame i was gobsmacked to discover that they had masked off the frame number and left that area bare metal.
I didn't ask for this so took it back yesterday (Wed) to get re done along with a couple of other small parts i wasn't happy with and then got an unexpected surprise call this morning to say it was all ready to pick up.
It's the first time i've used them and apart from that minor setback i'm very impressed with the quality and service so far
- PICT0419.JPG (336.36 KiB) Viewed 109072 times
Speedo mount, rear caliper hanger, coil mounts and front mudguard mounts in satin
- PICT0421.JPG (290.05 KiB) Viewed 109072 times
As are the seat base, battery box, back mudguard and mounts.
- PICT0422.JPG (300.4 KiB) Viewed 109072 times
Fitted the new tyres to the satin wheels over the weekend along with new bearing and seals .
- PICT0423.JPG (306.05 KiB) Viewed 109072 times
And built the rear mudguard assembly
- PICT0424.JPG (269.4 KiB) Viewed 109072 times
Which is now in position courtesy of some ally cup washers and countersunk stainless screws after going round the frame and chasing all the threads.
- PICT0425.JPG (291.84 KiB) Viewed 109072 times
Not much more i can hang on the frame until i find some crankcases to build the bottom end to drop in.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Little bit more progress on some random parts this weekend.
Cleaned the swingarm then drilled and tapped the pivot for a grease nipple and fitted new bearings.
I always set the bearings back a little from the end and fit 'O' rings that sit slightly proud in the gap around the bearing tube so that they press against the pivot caps and help seal against water ingress.
Repeated what i did on the alloy cafe and used a Triumph speed triple axle for the spindle, stainless hex bar for the screw in ends and machined some 4mm stainless plate to produce the washers. .
Triumph axle is 20mm narrower than the frame width so made the bolts with a 20mm dia 10mm step to make up the difference and center the spindle .
The hex on one end was left plain which i made a tight screw fit in the axle and was permanently loctited in and the other "nut end" machined with a detail recess to remind me which end unscrews.
Then moved on and refurbed the seat latch.
Stripped, blasted, painted, lubed then rebuilt with a little painted detail on the recessed arrow in yellow to tie in with the paint job when it gets done.
Then bolted in place with some fresh stainless cap heads
Battery box got rubber lined to fit and cushion the battery then bolted on along with the stainless tail mount pegs.
And the wheels completed with new discs, stainless disc bolts and even a new drive dog for the speedo.
Starting to look like something now.
Cleaned the swingarm then drilled and tapped the pivot for a grease nipple and fitted new bearings.
I always set the bearings back a little from the end and fit 'O' rings that sit slightly proud in the gap around the bearing tube so that they press against the pivot caps and help seal against water ingress.
- PICT0428.JPG (182.47 KiB) Viewed 108984 times
Repeated what i did on the alloy cafe and used a Triumph speed triple axle for the spindle, stainless hex bar for the screw in ends and machined some 4mm stainless plate to produce the washers. .
- PICT0430.JPG (218.82 KiB) Viewed 108984 times
Triumph axle is 20mm narrower than the frame width so made the bolts with a 20mm dia 10mm step to make up the difference and center the spindle .
- PICT0432.JPG (199 KiB) Viewed 108984 times
The hex on one end was left plain which i made a tight screw fit in the axle and was permanently loctited in and the other "nut end" machined with a detail recess to remind me which end unscrews.
- PICT0455.JPG (277.5 KiB) Viewed 108984 times
Then moved on and refurbed the seat latch.
Stripped, blasted, painted, lubed then rebuilt with a little painted detail on the recessed arrow in yellow to tie in with the paint job when it gets done.
- PICT0434.JPG (301.38 KiB) Viewed 108984 times
Then bolted in place with some fresh stainless cap heads
- PICT0435.JPG (280.96 KiB) Viewed 108984 times
Battery box got rubber lined to fit and cushion the battery then bolted on along with the stainless tail mount pegs.
- PICT0437.JPG (284.51 KiB) Viewed 108984 times
And the wheels completed with new discs, stainless disc bolts and even a new drive dog for the speedo.
- PICT0447.JPG (260.1 KiB) Viewed 108984 times
Starting to look like something now.
- PICT0441.JPG (312.21 KiB) Viewed 108984 times
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Crankcase crisis sorted courtesy of a set from club member Keefleaf 
.
Just needed some light cosmetic fettling with a pass on the mill and one lone iffy thread sorting and they are now ready to start again with the dry block mods then jet wash, blast, paint and prep for fitting the internals with hopefully no unforseen suprises this time round (fingers crossed)
.
.Just needed some light cosmetic fettling with a pass on the mill and one lone iffy thread sorting and they are now ready to start again with the dry block mods then jet wash, blast, paint and prep for fitting the internals with hopefully no unforseen suprises this time round (fingers crossed)
. - PICT0457.JPG (287.01 KiB) Viewed 108904 times
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Finally got the replacement cases plugged, blasted and painted with no drama.
Was going to use the HD studs out of the other set but they are in solid so had to wait for a new set of APE items to drop through the letterbox.
Then went on a rummage through my gearbox stash on the hunt for the best set of internals and was surprised to discover a real nice undercut cluster lurking in there that i didn't know i had
So pulled it apart and gave all the parts a clean in the bead blaster before washing and rebuilding with a billet 2nd gear, the best set of bearings ,shims and a new sprocket spacer from Zpower.
Next job is to give the welded z900 crank and the clutch basket a good clean and flush out, mill the ally bearing cap ready for a steel support plate and that should be everything ready to assemble the bottom end and get it dropped in the frame
Was going to use the HD studs out of the other set but they are in solid so had to wait for a new set of APE items to drop through the letterbox.
- PICT0469.JPG (238.13 KiB) Viewed 108704 times
Then went on a rummage through my gearbox stash on the hunt for the best set of internals and was surprised to discover a real nice undercut cluster lurking in there that i didn't know i had
- PICT0490.JPG (305.81 KiB) Viewed 108704 times
So pulled it apart and gave all the parts a clean in the bead blaster before washing and rebuilding with a billet 2nd gear, the best set of bearings ,shims and a new sprocket spacer from Zpower.
- PICT0475.JPG (239.6 KiB) Viewed 108704 times
Next job is to give the welded z900 crank and the clutch basket a good clean and flush out, mill the ally bearing cap ready for a steel support plate and that should be everything ready to assemble the bottom end and get it dropped in the frame
- PICT0483.JPG (243.93 KiB) Viewed 108704 times
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
Had a half hour spare today so used it to mill the hump on the main bearing cap level with the surface of the bolt holes.
Once the APE support plates arrive for both engines i can mill off their matching thickness ready for fitting.
I was going to make my own as i've done in the past but the cost of the correct grade of steel and additional faffing about cutting, drilling and machining hardly makes it worth the bother when they're only £23 each from Z1 Enterprises.
- PICT0494.JPG (254.35 KiB) Viewed 108660 times
- PICT0495.JPG (254.48 KiB) Viewed 108660 times
- PICT0496.JPG (291.89 KiB) Viewed 108660 times
Once the APE support plates arrive for both engines i can mill off their matching thickness ready for fitting.
I was going to make my own as i've done in the past but the cost of the correct grade of steel and additional faffing about cutting, drilling and machining hardly makes it worth the bother when they're only £23 each from Z1 Enterprises.
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
I wish I’d got you milling machine- and the room to put it in! Looking good!
Re: Double the troublezz. AMA style Racecrafters Z1000 and Moriwaki Z1R Turbo.
r3sc wrote:I wish I’d got you milling machine- and the room to put it in! Looking good!
This Harrison is a nice little machine but a bit limiting with no quill and just 15" of table travel but ideal for jobs like this.
Much better than some of the dodgy set ups i had to perform on the lathe though.
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