RZ350 TZR 3XV Hybrid

[kpke]

Hey guys, I said in the video no offense to you white wheeled MC folks, OK?.

12/17/23 EP5


I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat



After a meeting at the Professor’s house yesterday the boss puts his apprentice to work.

It begins looking like this.

Then goes on a weight loss program.

All done right?

No, needs a bit of grinding with a flap wheel. Never used one and boy what a great tool these flap wheels are.

All done right?

No, let’s do a little reverse spot facing on one of the magical machines in the Professor’s shop.

Left side on unit one.

And the left side on unit two.

Measure twice and cut once, right?

And a little trimming on the right side on unit one and two.

All done right?

No, let’s do some more magic on another giant machine.

All done right?

No, a final precision ream to make them holes perfect.

 

[kpke]

And back home safe and sound.

[YOUTUBE]rfnc_blQ_ZM[/YOUTUBE]

 

[kpke]

12/22/23 EP6

[YOUTUBE]J0E436gHUIQ[/YOUTUBE]


On a beautiful sunny December day, more grinding, sanding, filing, paint removal, at home in preparation for modifications.

12/23/23 EP6 continued

Back to Julian’s house where he exposes some motorcycle porn.

And the parallel project he is working on. With paparazzi cameramen all around recording the activities.

A well-deserved lunch break.

And back to work with a different rear end set up than what he is doing to mine.

A fixture used for locating and checking fitment of various components.

And back to the red frame.

 

[Jung]

Solid work, gentlemen!

 

[kpke]

Thanks Joe. I hope life down there is treating you well.

12/28/23 EP7

The tapered bearing races in the steering head require removal for powder coating the frame. I always put a nice little slot in the inside of the steering head above the races so that they can be removed after installation if required, BEFORE THEY ARE INSTALLED. This was not done on this frame after the ball bearing races were removed and before the tapered bearing races were installed.


[YOUTUBE]hsnx-26-66A[/YOUTUBE]


I used my porting tool to very carefully grind behind the races 180 degrees apart just enough to get a drift in to knock them out.

Not having ground out the groove before the races were installed…I had to clamp the drift to keep it from slipping off the edge of the race.

Success. And after removal finished grinding proper race removal slots.

 

[bobl]

Nicely done. I fought a race in an 86 Yamaha frame for hours with the same problem, no access. On Youtube, I found a vid that used a welder to heat the race, so off to Harbour Freight for a hundred dollar cheapie mig welder.
I stung a booger on the races for purchase with the punch, and the heating and cooling shrunk the race so that the punch knocked the race out easily. The top one even went flying across the garage. It of course ruins the race, but the old one was on no use anyway.
Quick and dirty but effective.

 

[kpke]

Thanks bobl. That is another technique for sure. In my case I am attempting to reuse the bearing races. The bike will be assembled and disassembled X amount of times plus I am uncertain if these are standard RZ350 replacements or if the previous builder used something else. And they are new.

 

[kpke]

12/30/23 EP8

[YOUTUBE]OrhwQSX6o4U[/YOUTUBE]

Front wheel clean up. Removing the rotor bolts revealed a rather strange situation. While these bolts were clearly blue loctited where the threads would contact the wheel, they also had a very hard plastic material on them close to the head.

This material was extremely hard and difficult to remove. It needed to be removed because the bolts would not drive all the way back in without binding. I tried using a heat gun which helped but this was going to take hours. Next, I clamped a nut into the vice and drove the screws in and out until all of the plastic material was removed. Here are some samples when I was chipping it off manually.

I have never seen this much Loctite (or something) applied to a bolt.

The front wheel is now cleaned up and the rotors are back on the wheel ready for preliminary assembly.

 

[kpke]

1/6/24 EP9

[YOUTUBE]BcVVg6PIrqg[/YOUTUBE]

It is time for some reassembly. Julian has a bunch of parts that he has designed and ordered enroute so this little project bike needs to become a roller.

There is no upper shock mount at the moment. So, the swingarm is flopping around. Do you see that custom component jammed between the swingarm and the frame? I designed that. And it is working quite well.

 

[augustiron]

That plastic stuff is a built up, leftover excess of Red loctite that hardened. Yes there are traces of blue on the threads also, but I have seen that hardened excess loctite turning into that exact shape on bolts before.

 

[Lonster]

That plastic stuff is a built up, leftover excess of Red loctite that hardened. Yes there are traces of blue on the threads also, but I have seen that hardened excess loctite turning into that exact shape on bolts before.

Agreed. Definitely excess red loctite. I hate it.

Quote kpke:
"Do you see that custom component jammed between the swingarm and the frame? I designed that. And it is working quite well."

Some of your BEST work brother.

 

[bobl]

Agreed. Definitely excess red loctite. I hate it.

Quote kpke:
"Do you see that custom component jammed between the swingarm and the frame? I designed that. And it is working quite well."

Some of your BEST work brother.

At last, a component I could make!

 

[kpke]

Thanks for the compliment on my 2x4 design. Let me know if you'd like one of those brackets.

1/7/24 EP10


[YOUTUBE]WDVXvVolk7A[/YOUTUBE]


Back to Julian’s shop. Here he is measuring the angle of the swingarm. And as it turns out the piece of 2 x 4 needed a very slight trim to get the attitude of the suspension where it needs to be.

Next up is getting the bike into the shop for a bit of welding.

Forward tank mount parts are fixtured and ready to be tack welded onto the frame.

When I grow up, I want to learn to do this.

And trailer the thing home for a little more paint removal and test fitting of the fuel tank.

This week Julian is going to work on utilizing these cool parts that just arrived to assemble a couple of rear sub frames for this bike and one of his. Your hard work and brainpower are very much appreciated Julian!!!

The parts in the photo below are all designed by Julian. Files are sent to the source and this is the result. Really quite beautiful fabricated components.

 

[kpke]

1/27/24 EP11

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Back to Julian’s shop for more mods.

I got an update on some of the mods he has done to his bike.

My bike came over looking like this.

And left looking like this. Progress, eh?

 

[Jung]

These two are looking great. A updated YPVS on sticky 17" rubber sounds fantastic.

 

[kpke]

Thanks Joe

1/28/24 & 2/2/24 EP12

[YOUTUBE]AJTS57jL4Pk[/YOUTUBE]


Stopped by Julian’s house to look at some progress on his bike.

Back home reassembled the chassis back to a roller.

And then assembled a dummy engine for fitment of more parts.

 

[kpke]

2/10/24 EP13

[youtube]jVMixF8GgF0[/youtube]

Stopped by Julian’s.

He was doing some bending of parts and machining tubing of subframe parts.

More send/cut/send parts arrived. Many thicker gauge “special” parts that he designed and ordered for my bike.

 

[Frame Maker]

That last picture looks like Christmas morningarty

 

[Jung]

The pre-bent bits from Send Cut Send look really good. I'll have to give that a try one of these days...non-existent cad skills have been the only thing that has put me off to date.

 

[Frame Maker]

...non-existent cad skills have been the only thing that has put me off to date.

No need to worry, SCS now offers in-house CAD service. They will convert your napkin sketch or old school CAD (cardboard aided design) to laser ready CAD.

https://sendcutsend.com/services/design-services/