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Post by captainpooby on Nov 26, 2015 8:26:32 GMT -5
My goal is to have a King Cobra ported motor in a modern chassis. I started with a 93 roller, which was a mistake actually. Without thinking, I had begun a double restoration which was not in my plans but here I am today. Started as a 200 buck, titled roller. I powdercoated the frame, swing arm, steering head....well, everything. The frame is "magic black" rear brakes are Brembo gold. I did all the bead blasting myself, powder was done by Specialty Powdercoating in Zephyrhills Fl. Replaced every bearing and seal and nearly every nut and bolt. I replated the rest of the hardware with zinc myself. Fitted ZX10 forks and brakes, had to shim the upper triple and mill the lower. Working on front wheel fitment now. I didn't do enough research and picked the bastard year for ZX10 forks. Now I have to fit new wheel bearings again, and machine some spacers. This what I started with:  Parts bead blasted and ready for powder. I did all the bead blasting except the frame, which wouldn't fit in my cabinet.  Frame assembled:   Swingarm assembled to new specs, all seals, bearings and guard installed.  I fitted 04-05 ZX10 forks which required shimming the upper triple and machining the lower. There are other ways to do it, but that's the route I chose.  Here's a shot of the upper triple I had machine just for bling purposes, I think it looks cool but it's not even for lightening, just looks.  Rear caliper, fully rebuilt and powder coated to Brembo gold. New seals and bushings in the torque link. The bearing for the hanger is an obsolete part so it remains. Most bikes don't even have a bearing in that place so I'm OK with it.  Rebuilt and powder coated rear master:  Pics of the whole shebang. Rear wheel and forks are installed, front wheel is fitted for fabbing, not installed. A couple bits of obligatory gold bling from China. The bling may not make the final cut but it looks good, no?      The engine work is mostly done, trans has been undercut by R&D in St Petersburg, and barrels ported by Tony Nicosia. I have yet to install the reeds fro JaMoo. Then off for powdercoating and then assembly of the motor. I'll post pics of this process as it moves along, expect long wait times though, this project is taking far longer than I planned, I'm already over a year into it. Body work is sanded and ready for paint, just haven't got to it yet. I needed to get this out of the way first. If I were to do this over, I'd pay for a more modern roller that didn't need resto. :shock: |
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roadrash
2nd Gear
10 McNab St.E. Port Dover
Posts: 272
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Post by roadrash on Nov 26, 2015 11:54:13 GMT -5
Looks good Billy,for a Florida guy!
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Post by Walms on Nov 26, 2015 12:10:57 GMT -5
Cool project! How much does the roller weigh?
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Post by captainpooby on Nov 26, 2015 14:59:32 GMT -5
Hello Paul, I hoped you'd see this! 30 some years ago you kinda inspired this build when I was an apprentice. Hope it meets your approval.  Walmsy, I have no idea how much it weighs but I haven't done anything to lighten it either. I figure the bike will weigh about 40 lbs less than a ZX7 when it's done, about the difference in motor weights I'm guessing. I have those numbers somewhere. Did a little work on her today so here's some more pics. Some fitting will be required for the calipers, They'll need to space out about 9 or 10mm. That brake line is actually just the rear line I put on so I could pressurize the calipers to center them. There will be new lines fitted to the final bike. The axle is also not correct, I just have it there for roughing in the brakes.   Here's the ZX6R shock I fitted after I painted the spring green. I had to drill out the clevis and grind some of it away to fit on the link. It's 20mm shorter but in my pile of parts I just happen to have an adjustable dog bone that I can use to adjust ride height later.  I at first tried a ZX10 shock but I didn't like the way the reservoir stuck out. The original shock was not useable due to a damaged piston.     Here's a better look at the top triple. You can the shims I made to fit the forks. The ZX10 forks are 50mm as opposed to 52mm for the ZX7. That's 1mm thick sheet aluminum.  Since this is a triples forum, here's some pics of the engine. This is not assembled, it's just together for fitting in the cradle.     Signed by the man himself, Tony Nicosia.  |
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browney
2nd Gear
Goin' Crazy Wanna Come............
Posts: 361 
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Post by browney on Dec 3, 2015 10:01:30 GMT -5
Looks like a great project. How are you going to join the engine to the frame? Any pics? browney out  |
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Post by drewski on Dec 3, 2015 12:21:56 GMT -5
Since this is a triples forum, here's some pics of the engine. This is not assembled, it's just together for fitting in the cradle. Great project!! The frame/wheel color combo really work, IMO!  From this comment in an earlier post, I assume you're crafting some sort of framework/cradle to wrap the engine and bolt to the stock engine mounts. My guess would be that the cradle will hang from the zx7r chassis, correct? I actually pondered such a project a few years ago with the same chassis as my foundation. I considered hanging the engine in the zx7r frame in a similar way that the zx7r engine is hung. There was lots of 'debate' about the wisdom of such an approach.  I ended up selling the zx7r and moved on to 'simpler' things. It was fun to dream, scheme and plan though!  I'll be watching with keen interest to see where you go here! |
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Post by drewski on Dec 3, 2015 12:29:34 GMT -5
WAIT A MINUTE....
upon further examination, I think I see an engine cradle in this pic! 
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Post by captainpooby on Dec 3, 2015 17:24:04 GMT -5
Nope. You didn't see a cradle there, here is what I did. This actually the first of two I made. I still might re-do it, I learned a lot during the fab process.  It took me two tries and many, many hours to get to where it is today and like an idiot, I didn't take any pics of the latest version. There is an inherent problem with this frame/engine combo and the method I chose. There are clearance problems with the top cross bar/cylinder heads/spark plugs/frame and getting the chain alignment correct. Aligning both the chain/swingarm height and sprockets front to back. An earlier frame has a more forward mount which would have allowed me more leeway. As it is, the engine has a pretty decent forward cant and I'll have to deal with trans oil level now.   |
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browney
2nd Gear
Goin' Crazy Wanna Come............
Posts: 361
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Post by browney on Dec 3, 2015 20:55:15 GMT -5
Kewl those pictures explain a lot on how you are going to fuse this altogether . Reinforcing that tube frame will probably be done also I would think. Lots of torque and vibration might bend the tubes after a while. Looking forward to seeing your bikes development as you go along. browney out |
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roadrash
2nd Gear
10 McNab St.E. Port Dover
Posts: 272
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Post by roadrash on Dec 4, 2015 12:02:17 GMT -5
Just a thought.Why not run the center tubes down from the outer edge of the cross over tube to the top crank mounts then back. Or leave those tubes off and just run a cage around the transmission to those double bolts above the rear trans mount.There's not much reason to bolt the cylinder/heads to the frame. |
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Post by triplepoweredgpz on Dec 4, 2015 12:12:49 GMT -5
Are you gonna run the pipes up where the old air box was? I've seen people do it...nice project!
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Post by drewski on Dec 4, 2015 21:40:31 GMT -5
Nope. You didn't see a cradle there Well, there's something there!! Just a thought.Why not run the center tubes down from the outer edge of the cross over tube to the top crank mounts then back. Or leave those tubes off and just run a cage around the transmission to those double bolts above the rear trans mount.There's not much reason to bolt the cylinder/heads to the frame. Ya, I've never liked the front down tubes. I was contemplating a beefy L-arm bracket underneath on either side to support the engine from the rear and lower mounts. I never got to test this design theory out but part of me would like to. |
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Post by captainpooby on Dec 6, 2015 8:18:27 GMT -5
Just a thought.Why not run the center tubes down from the outer edge of the cross over tube to the top crank mounts then back. Or leave those tubes off and just run a cage around the transmission to those double bolts above the rear trans mount.There's not much reason to bolt the cylinder/heads to the frame. I'm not bolting the heads to the frame. As to why I did it the way I did, sadly, that is about the limit of my imagination and skills as a fabricator. Seriously though, that was the easiest way to make it work with what I available at the back in the ZX frame. It's not very wide back there. I didn't want to have a compound angle to deal with joining the tubes. It took me 2 1/2 tries, first try I gave up halfway, second try I trashed after I made it, and I kept the third try. those pics are of the second try. One idea I had was taking an H1 frame and cutting out the cradle and fitting it to the ZX. |
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Post by drewski on Dec 6, 2015 22:09:13 GMT -5
Just a thought.Why not run the center tubes down from the outer edge of the cross over tube to the top crank mounts then back. Or leave those tubes off and just run a cage around the transmission to those double bolts above the rear trans mount.There's not much reason to bolt the cylinder/heads to the frame. I'm not bolting the heads to the frame. As to why I did it the way I did, sadly, that is about the limit of my imagination and skills as a fabricator. Seriously though, that was the easiest way to make it work with what I available at the back in the ZX frame. It's not very wide back there. I didn't want to have a compound angle to deal with joining the tubes. It took me 2 1/2 tries, first try I gave up halfway, second try I trashed after I made it, and I kept the third try. those pics are of the second try. One idea I had was taking an H1 frame and cutting out the cradle and fitting it to the ZX. Ahhh... I think with a project of this quality, you need to do something more exotic than that. Let's get the "KTC Innovators" spit-balling on this and see what emerges. |
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Post by triplepoweredgpz on Dec 6, 2015 23:15:11 GMT -5
 I know you said you didn't want to go off the heads...but this fella did, looks pretty cool |
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I'll be watching with keen interest to see where you go here! 
