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1400 Mk2 Restomod

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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Bevelhead
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Re: 1400 Mk2 Restomod

#46 PostAuthor: Bevelhead » Tue Jun 28, 2022 4:59 pm

KWACKERZ1 wrote:Thats looking good with the arm in, my gpz project has an XJR Arm
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Must start working on it again at some point soon. Just looked at my project thread and I started it in 2017 :oops:
I blame my ADD :D :D


Did you powder coat the swing arm.. think I'll try to ensure the area behind the adjuster blocks isnt coated, as would soon get scratched up.

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Bevelhead
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Re: 1400 Mk2 Restomod

#47 PostAuthor: Bevelhead » Thu Jun 30, 2022 5:06 pm

The custom seat has arrived from Japan, a bargain as its pillion strap was missing, no problem, as I don't fit them anyway. The rear caliper mount is done though it needs a little more work to make it look better..

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Re: 1400 Mk2 Restomod

#48 PostAuthor: Bevelhead » Sat Jul 02, 2022 12:12 pm

Collected some parts from Camcoat who ceramically anodised them, including the billet alloy engine mounts and cam cover plates for the MK2. The latter are needed as the cam cover came from the US and included an ugly anti pollution gizmo in the cover. It was machined off, and so a pair of plates were needed, to cover the holes which are drilled through the cam cover. Unfortunately a misunderstanding at the powder coater meant the machined area was masked off and not coated. So now have a small amount of bare alloy around the plates. I tiny paint brush and engine paint will fix the oversight.

The new alloy engine brackets were test fit to the frame with expensive stainless fasteners from Pro-Bolt. The new stainless engine bolts aren't finished, as need to use a friends capstan lathe and Coventry box to cut their threads, and he is super busy, so don't want to bother him yet.

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Bevelhead
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Re: 1400 Mk2 Restomod

#49 PostAuthor: Bevelhead » Sat Jul 09, 2022 6:55 am

Finished machining the caliper mount for the Z1000A1, it'll be hard anodised later. Moving to the front end, the Z1000 stem has had a threaded steel plug welded into its base, next a spacer needs to be added which will be a press fit into the Z900RS lower yoke.

Bought a head for the engine, in good condition, with its cam caps, but valve seats will be recut, with new valves etc.

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Bevelhead
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Re: 1400 Mk2 Restomod

#50 PostAuthor: Bevelhead » Sat Jul 09, 2022 7:37 pm

Today split the cases for the Z1000A1, and checked them very carefully for any damage or cracks, thankfully they look ok. So the cases, cam cover and sump cover can be taken to be ceramically coated in the week. While the barrel will need to be bored out by 1mm to suite the new pistons, and the head needs its valve seats recut. Then they in turn can be coated.

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Re: 1400 Mk2 Restomod

#51 PostAuthor: Bevelhead » Fri Jul 22, 2022 10:25 pm

Found a pair of headlight brackets I liked for the MK2, they can be fitted without dropping the stanchions in the yokes, but sadly the back of the clamps hit the tank on full lock, so they cant be used. Therefore, since I had an original ugly ZRX1200 headlight/fairing mount, I've sketched out a better looking version, and bent a piece of 7mm steel rod to make a sort of cage, similar tot hat used on the KZ650. Just taken it to my local welder to have him complete it, and fab the all important mounts to bolt it to the existing cast mounts which are part of the ZRX1200 yokes. I took along the ZRX mount to use as a guide as to how the mounts should be made.

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Test fitted the new headlight bracket to the Mk2.. will fit fine once I space it out with some neoprene washers, along with spacers between the bracket and lower yoke. The original ZRX bracket used thick rubber grommets which need to be accounted for. Next need to make a pair of alloy 'ears', to bolt to this bracket which will hold the headlight.

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Meanwhile, took a trip to Maxton Suspension to collect my custom built shocks.. very nice. Cant fit them yet as the upper shock mount uses spacer/threaded jet style nut to move the mount out to match the wider swing arm. The ZRX shocks fitted originally had their top mounts modified to fit the now 18mm extension. Standard Zeds use a 14mm top mount, as does my new Maxton shocks. I wasn't happy with the 'extenders' that were fitted, so will make something better in one piece not two, complete with a standard 14mm top mount.

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Re: 1400 Mk2 Restomod

#52 PostAuthor: Bevelhead » Wed Jul 27, 2022 5:23 pm

Have been slowly buying new and used parts to build the Z1000A1 engine. Bought this 1015cc block, like most of on Ebay it had a broken fins, this one was one of the better blocks for sale..

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So took it to a friend who filled the broken area with weld, then we carefully filed it smooth, looks good as new. Next I'll have it bored out by 1mm to suite the new pistons, and finally it needs to be ceramically coated, same as the cases. The rest of the engine is going to be silver, but might have the block coated black... not sure yet.

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Re: 1400 Mk2 Restomod

#53 PostAuthor: Bevelhead » Sat Aug 20, 2022 7:27 am

Started work on the 'ears' of the headlight mount for the MK2, started with 50mm thick billet, they need to be narrowed my 15mm, then a lot more work on the miller to make them look better. Once I'm happy with them, they will be hard anodised black..

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Re: 1400 Mk2 Restomod

#54 PostAuthor: Bevelhead » Wed Aug 24, 2022 9:44 am

Got the Z1000A1 cases, cam cover and sump back from a local specialist who gave them a silver ceramic coating, very pleased with the results. The cylinder head couldn't be coated at the same time, as it was away at a local machine shop having its valve seats recut and getting a mild skim.

I unwrapped the head to see if the colours matched with the cam cover, as then perhaps it didn't need an expensive ceramic coating too. It looked pretty good..

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However when I unwrapped the cylinder head for the first time since it came back from the machine shop, things weren't so good... they had somehow managed to break four of the fins. A pita as it took me months to find a head on Ebay which didn't have any broken fins. I think it can be repaired , not sure what's happened, but looks like its been dropped? The machine shop has a good rep, and normally they work on classic Porches, Astom Martins etc .

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r3sc
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Re: 1400 Mk2 Restomod

#55 PostAuthor: r3sc » Wed Aug 24, 2022 11:43 am

WOW, I’d be seriously upset by that! I hope the machine shop are going to pay for all reparations!

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chrisNI
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Re: 1400 Mk2 Restomod

#56 PostAuthor: chrisNI » Wed Aug 24, 2022 12:39 pm

Looks like it’s been rolled - looks like there’s a broken fin on the other side also… :shock: ?

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Bevelhead
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Re: 1400 Mk2 Restomod

#57 PostAuthor: Bevelhead » Wed Aug 24, 2022 3:14 pm

chrisNI wrote:Looks like it’s been rolled - looks like there’s a broken fin on the other side also… :shock: ?


Yes its got a broken fin on the other side as well. Haven't told them yet, as waiting to get an idea of the cost to fix the issue. I now someone else who had the same problem recently, seems an apprentice dropped the head, but the boss paid for the repair no problem. Suspect the same thing happened with mine, but the apprentice didn't tell the boss, while the head was carefully wrapped in bubble wrap when I collected it, and I didn't unwrap it until yesterday. Lesson learned, should always check parts when I collect them.

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rpeters
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Re: 1400 Mk2 Restomod

#58 PostAuthor: rpeters » Thu Aug 25, 2022 6:12 am

Welding that could be dodgy as it would be very close to the oil gallery
paid up member

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Bevelhead
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Re: 1400 Mk2 Restomod

#59 PostAuthor: Bevelhead » Fri Aug 26, 2022 5:09 pm

Even without the engine installed, I think I can built approx 80 or 90% of the bikes wiring. To start managed to use an existing mount to fit the rectifier underneath the right hand side panel. No such luck on the left hand side, where I want to mount the M-Unit Blue, so made a start on making a mounting plate which will utilise a pair of existing captive nuts. Next, had to make 4 spacers to mount the Dyna coils in the OE position.

Test fit the headlight on its new mount, still needs more work to improve the looks and be able to mount the front OE indicators.

Have a matching pair of Motogadget micro switchgear on order, when they arrive can drill the new Renthal handlebar for their wiring, and fit the bars and the new HEL brake and clutch Master cylinders to the bike.

The instruments are a headache, as want to use OE looking set, but they are mechanically driven, which can't do anymore on my bike. I can buy an OE electronic tacho but no one seems to make a matching speedo. More thought required.

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Mathh
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Re: 1400 Mk2 Restomod

#60 PostAuthor: Mathh » Fri Aug 26, 2022 8:29 pm

I bought a set of electronic Speedhut tacho and speedo's from the States to fit inside the stock housing. The speedo uses a GPS antenna to calculate speed. The tacho gets a signa from the coils. Fittin however is not plug and play .. I had to make some teflon cylinders to fill up the gaps inside the housing ( a rather precise job) and glued them together before fitting the rvs ring again.
Here some pictures before closing the housings. If you want I can post some pictures from the finished products.

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