My First Kwack build - To do List

Here's a chance to show off your zxr400, so get them digital cameras out and show us some piccies.Rebuilding your bike or modding it then let everyone in on it.

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Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

1182414IcFVBF6B.jpg
Dick!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

So today i have been mainly....

Looking in the top of the engine,
top enginw.jpg
Looking at Carbs, full of water and rust, no wonder it ran rough!
dirty carbs.jpg
then cleaned :excited
clean carbx.jpg
except the small carb fuel filter thing, which were all seated with PTFE tape, which had turned into the texture of melted cheese! I'm still surprised at the level of bodge this bike throws up!

On the lookout for some side fairings if anyone has some lying about!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Paint, paint, and more paint!

Fork bottoms ready for priming,
fork bottoms.jpg
discs ready for priming
6152259Hs4q75GW.jpg
Calipers, primed and baking!
brakes in oven.jpg
Soooo, any advice on a cheap and easy way to remove powder coat from the frame, and I can't emphasise CHEAP enough! Someone say something, all 100 of you stop viewing and say Hi!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
User avatar
mark400
Posts: 208
Joined: Fri Feb 06, 2009 11:48 pm
My Bike: Building an original SP

Re: My First Kwack build - To do List

Post by mark400 »

Hi there,

Have you tried paint stripper ?
NG Road Racing Champion 2012 400SS
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Since nitromors changed their formula, it doesn't work half as good. Down to sanding it off.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Top-shaggy
zxr400 oc member
zxr400 oc member
Posts: 128
Joined: Sat Aug 30, 2014 12:03 am
My Bike: KR-1R
Location: NE Derbyshire

Re: My First Kwack build - To do List

Post by Top-shaggy »

Great idea with the oven .. I've stolen the sink, the dishwasher, the freezer, kettle, hairdrier and all manner of cutlery working on the bike..

Never used the oven.. Wifey would have a fit if she saw it like that. Great stuff. biggrin
We are we're we are..
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

The garage was freezing and no way to heat it constantly. Luckily the missus spotted them in there before putting the tea on! Banned from using the dishwasher after cleaning a top end and hangers, pegs etc. The next dinner had a faintly oily taste! Luckily my mate has a bike shop, so I use his solvent bath and tools for hard stuff. Still need the sink and fairy to get it prepped for paint though.

Soooo,

Discs are painted, ford Champagne gold,
painted discsI.jpg
Calipers painted, bolts cleaned, pistons wire brushed,
calipers apart.jpg
and put together, lovely jubbly!
calipers doneL.jpg
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

I have been a busy boy on these bits too....

Fork bottoms painted, metallic black and lacquered,
fork bottomsr.jpg
Frame has gone from this...
frame.jpg
to this...
sanded frame.jpg
Covered in ali and black plastic dust. Need a wire brush and drill to get in the fiddly bits. I know what I'm doing next week :smt009

Things still to do: Get the oil emulsion out of the engine,
sort out why it isn't firing on number three,
powdercoat the wheels,
paint and sort hangers, pegs and frame.
Source some side fairings,
Find out where I can get the old school green/blue/white paint scheme.

Answers on a postcard to.....
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

I think I now have white finger syndrome! Sand, wire brush, polish, I've had enough of power tools.... So, pics;

Raw frame
raw.jpg
120 grit sandpaper
120.jpg
180 grit
180.jpg
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

240 grit
240.jpg
320 grit
320.jpg
Now on wet and dry :smt015 On the plus side, the swingarm is polished and looks great!

Caustic soda in the exhaust for a week, look what comes out lol
24215219AOyTBdTK.jpg
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

So, wheels are powdercoated, although I seem to of misplaced the disc bolts, Grr!
front wheel.jpg
rear wheel.jpg
both with angled valves....its the little touches! :tease
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
JamieNeve
Posts: 197
Joined: Fri Jan 25, 2013 12:33 pm
My Bike: CBR600RR, ZXR400 L-2
Location: Waterlooville, Hampshire

My First Kwack build - To do List

Post by JamieNeve »

Really enjoying the thread, keep it up! And if you are still looking for farings, I have a rear, right hand side fairing panel. It has been rattle canned horrifically, but apart from that is in perfect condition, if you are respraying, it will do the job fine! You are welcome to have it if you pay the postage!
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Cheers Jamie, unfortunately lack of funds are coming into play! I'll pm you as all my panels are different colours! Shims still haven't been looked at, although the dodgy exhaust smoke has now been allocated to leaking exhaust valve seals. Plus side today is one fork is together with its 5W oil, need to compress the spring on the other as i completely took it apart, which needs five hands and superhuman strength! Downside is that Pete distinctly remembers me putting the disc bolts back in the wheels, so either the powdercoaters have taken them, or they are somewhere in the garage :smt009

Forks and frame tomorrow, wish me luck!
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
JamieNeve
Posts: 197
Joined: Fri Jan 25, 2013 12:33 pm
My Bike: CBR600RR, ZXR400 L-2
Location: Waterlooville, Hampshire

My First Kwack build - To do List

Post by JamieNeve »

Forks are the only thing i'm not brave enough to take apart! Good luck on the frame and getting that fork back together! :)
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

So... found the bolts in the back of the boot, Pete has a special tool that compresses forks,(Bikes and Bits, Ashton under Lyne) so all back together.

So bottom off the sump shocking
sump gasket.jpg
and bottom open
dirty sump.jpg
but all looks good
open sump.jpg
You do not have the required permissions to view the files attached to this post.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
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