03 zr7s revamp

Discussion in 'Some Assembly Required' started by sh0rtlife, Jan 11, 2012.

  1. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so i picked up a wrecked for atleast the second time 03 zr7s..fairing gone tank dented and the usual scrapes and rash but its got a hefty list of new/mods and i really didnt spend anything on it..runs like a dream

    i hope this is the right spot for a rebuild

    heres a list of what was put on it BEFORE i got it...all of which was done around 3 months ago
    coil
    plugs
    full fluids and filter
    battery
    ignitor

    and before that
    k&n
    micron slip on
    corbin seat
    rear tire
    front brakes
    fender eliminator

    its a solid platform all of the damage was very cosmetic..however trying to locate a decently priced fairing and tank i went scavenging and found some interesting plastics..are they old..probably.... but im digging the look ..ive got 80$ wrapped up in
    right foot peg
    full upper lower front fairings
    clipons from a cbr

    so not bad but ive got my work cut out for me..cleaning road rash and making the new plastics find as well as re-work and repair them..allready started on stripping paint from the old fairings...if anyone can ID the fairing bits please do

    and for thos who just want to look at the pic's heres a spam of shots

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    #1
  2. LuciferMutt

    LuciferMutt Rides slow bike slow

    Joined:
    Aug 19, 2008
    Oddometer:
    11,589
    Location:
    New(er) Mexico
    Interesting project. Keep us posted! I think it's cool when somebody brings a bike back from the brink of death like that.
    #2
  3. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so i started making mounts last night..some of the pic's may not exactly make sense most of them are before and afters....got the whole lower fairing mounts made up and in case of the rearward mounts welded to the frame...nothing that couldnt be easily reversed....the lower fairing had to have a small section out for the exhaust in both the side and the front..just no 2 ways around it..then stripped and temp shot with castiron color...gotta wait a couple months for some heat as my shop aint heated before i can lay REAL paint
    started making tie connections for the upper fairing as well as straightened the stock upper mount as i will likely be using atleast part of it

    the clipons are really giving me hell with the fairing...i may either swap them again with a set that isnt "offset" forward its that forward offset thats the issue not the drop..besides there seems to be ALOT of diffent clipons even ones with more rise than the stock bars.....worst case ill go with a flat style bar


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    #3
  4. CafeRacer

    CafeRacer Been here awhile

    Joined:
    Sep 15, 2006
    Oddometer:
    258
    Location:
    City of Angels
    Excellent.
    #4
  5. GB

    GB . Administrator

    Joined:
    Aug 16, 2002
    Oddometer:
    57,517
    Location:
    Toronto
    Moving this our newest forum, Some Assembly Required. :thumb
    #5
  6. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    ahh good on the move..wasnt sure if it should have been over her cause its not a full rebuild just an "add on"

    nothing to spectacular today but..still steppin forward....cut and pulled the stock speedo mount back almost 2 inches to bring it inside my new fairing made up a pile of mounts most things are tacked not full welded.....i have a plan for the headlight/s just gotta get up to my main shop and pick them up

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    #6
  7. TerraRoot

    TerraRoot Adventurer

    Joined:
    Jun 8, 2009
    Oddometer:
    61
    looks pretty good, tail could do with a bit of shortening to match the front axle over hang :thumbup
    #7
  8. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    sure "if" i could trade this corbin seat for a single corbin seat id totaly do it!!!
    #8
  9. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so i made a run up to my big shop for supplys and such(nuts bolts aluminum) as well as my stashed set of headlights from a 95 diamante...they arnt actualy the full diamante headlights but once you get in past the main lens you find these lil units that take 9004-9005-9006 bulbs...(low/hi, low only, high only)...the ride was..well intresting to say the least...i expected "some" snow as i had a light dusting down here but the shop is 1500 feet up from home at 33miles away...my lil honda xl600r taking most of it in stride but the very street tires put me down..twice at very very low speed sliding down hill sideways..and fighting for traction to climb back out..add to that trying to right the bike and having the whole bike slide away as my boots try to slide out from under me...fun trip lol....

    anyway the aluminum sheet will form up under the front fairing wrap over the headlight area and on up where the windshield would be...im not sure if ill even run a windshield as of yet....will see once i have the sheet in and see if i fit into it in such a way to even warrant something to see thru...the headlights i simply set into the frame to get an idea..yup they will do nicely

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    #9
  10. Transalp Jas

    Transalp Jas Been here awhile

    Joined:
    Feb 13, 2006
    Oddometer:
    807
    Location:
    Corner Brook,NL
    Interesting. Looking forward to seeing how this project comes out.
    #10
  11. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    HUGE leap forward..
    so i started out working with a gap fil bit of aluminum to fill the headlight area and windshield are and ran into alot of issue..but kept rolling with it...it was working untill i checked and test fit the speedo...DOH!!!!...so i lopped it off just past the first set of bolts for now..and tracked down that the fairings are for an 88 ninja 600r and found a cheep windshield off ebay...ill likely have to heat it up and put a hump in it but thats easier

    some braces got added here and there..the front fairing mounts are SOLID...solid enuf to stand on..try saying that about the stock setup that was on the bike LOL.....some extra bracing down low as well to help pull th fairing offthe engine a bit more

    next up..my headlights...from a 97? diamante ..they are the inner "high" beam lights ..you would never notice them unless you busted out a headlight and found them by mistake...i think they suit the front of the bike beautifuly...not to big not to small...and once i make a fill panel for them they will look perfect..i never likes the 80s ninjas and there huge single headlight....anyway i took some cues from italian car headlights being a full floating unit riding on VERY stiff springs and duplicated it so that the headlights are fully aimable

    all welding ON the bike is done..so i re-connected everything up as i had dissconnected all primary things so welding couldnt damage them...once done i started bolting everything up so that i can make a count of size and length of bolts so i can swap out all the hardware that was not only missing but also the stuff ive added with allen button head type that ill pickup tommaro....so whats left to weld is the front headlight fill and 2 mounts on the tank..thats really it...fired it up and everything still checks out....now im hunting for some turn signals and mirrors..and a wait for things ordered


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    #11
  12. zuk16l

    zuk16l Adventurer

    Joined:
    Dec 21, 2006
    Oddometer:
    95
    Location:
    Milwaukee, WI
    Awesome job! These are always my favorite threads. Subscribed.
    #12
  13. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so i finaly got sick of looking at that damned yellow tank....and started swapping out hardware for allen button heads.....im semi stuck waiting for stuff to show up so i rolled her out into the back yard to clean out the shop..nothing too great to see here...i did get the turn signals all wrapped up tho i am going to black out the back half of the new fronts and the front half of the rears


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    #13
  14. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    well im stuck waiting for stuff..but my lock set showed up today as well as my drag bars..god they are comfy but i want to weld in the 1 inch or so bar end+ extension that was on the old bars..in fact i NEED it on the throttle side

    i shimmed the seat lock so its more "flush" mounted had to change the lock cyl on the helmet lock as the new one wouldnt fit which ment picking the old lock too..lol that was way too easy..the new ignition looks really nice ....the bars fit like a tight glove...just as the brake/clutch left hit the fairing it hits the bump stops..so...its perfection

    started making a mock up headlight pan to filler out then make a mold from ...its bit me a few times ive got the grinder gouges and destroyed discs to show for it....the 4.5 inch hole saw descided NOT to cut into the sheet..even mounted on my drill press running reverse or forward made no lick of differance so i had to cut a round hole with the angle grinder useing the hole saw marks as a guide..much fun..then used some stacked wheels to make the holes bigger..as the initial hole was smaller than the size of a disc..the holes will be frenched for the look that i want

    figured since i needed to check vac lines if i was going to pull the tank i may as well sync the carbs...funny story in that...several years ago when i was building the gamer bus for a friend..i helped him move up a state..while packing etc one of his room mates was also moving ..being the pack rat that i am i love helping ppl move as you tend to bring home intresting stuff...so he is like you want this thing..pointing to the motion pro sync tool..and im like well i dont ever have any plans on gettting a bike with more than 1 jug n slug let alone a crotch rocket..but sure ill give it a good home......its been sitting on my shelf in a box collecting dust for longer than i know...so i synced up the carbs they wernt that far out actualy

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    #14
  15. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so i finished the initial "base" for the headlight cover....now KEEP IN MIND that this is NOT the final product it is something to make a MOLD from so i can make the final out of F-glass

    the base metal has 2 frenched pockets for the lights ..you will note they dont go all the way around due to adjustment needs and such..so never mind that...
    the body got masked up not to protect it but to keep the filler from sticking so that it will be a perfect match..well a perfect re-match to my own design...yes i did some sanding with it in place and trashed some paint..no bigy ill go back and re-temp paint the uppers and front fender once the headlight chunk is all done
    3 layers of filler to get it built up enuf to sand and mold for making a revere mold and then copy out of that

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    #15
  16. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    so my headlight panel was starting to really take shape and it was working..i was within a couple hours of having something i could make a mold from and a thin light weight replacement..

    the ups man came a knocking with my windshield...and the shit hit the fan..seems i had made the entire front of the fairings almost 2 inches wider than it should be..so...it would seem i built myself into a corner..pissed off i tossed the headlight section id built over my shoulder fit the windshield up and got pissed..re-adjusted all the forward mounts and got ready to start over.....do ignore the graphic work on the windshield as its going to have to be cut for my body frame and helmet space so it WILL get painted black

    pulling the front end narrower resulted in it coming forward about an inch so all new upper mountings had to be made..nothing special

    while scratching my head on materials i made up a relay set and wireing harness for the new headlights

    it hit me..ive worked with plastic when i was younger with model cars and such with EXTENSIVE modifications ..so joining and modding plastic is no big deal..ad i have a tap plastics inc neer by ..also eary on in the mold work i knew that a 4inch abs pipe coupler was the right depth and size to be used as headlight french tubes..so i went and grabbed a pair and hit tap for a 1foot by 1 foot chunk of abs plastic and went to town trimming gluing heating and bending....in a day i made more headway with the plastic than i did with the old setup..ahh well

    when all is said and dun the plastic panel will look pretty much like the old mold i was making

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    #16
  17. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    the new headlight sections coming along nicely..the fit is great..and ive got it "mostly" trimmed down..going to need a smidge of filler but overall im loving it........the relays are tucked with a welded tab to the fairing section..and the headligths are...BRIGHT..nothing i own is this bright hell take any 3 cars i own and still not bright enuf...that said i was able to take it for a ride today ..a few rides to be exact and put about 70 miles on it... had one guy comment saying "you look like your ready for war with that thing"


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    #17
  18. Ron Bullard

    Ron Bullard Been here awhile

    Joined:
    Apr 9, 2008
    Oddometer:
    153
    Location:
    Los Angeles, CA
    Awesome project! :D:lurk
    #18
  19. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
    glad im keeping everyone entertained :evil

    in the past 2 days ive put close to 200 miles on her..theres a light howl up front..seems to be brake drag echoing into the front fender...unless someone has any other thoughts...had her into the triple digits and LOVING every second...but the front end feels a bit..unsure footed ..atleast compared to my dual sport on street tires

    today she saw 60 deg sun, heavy rain, 10 miles of gravel, some snow, some mud, and a bunch of back roads and some hwy
    #19
  20. sh0rtlife

    sh0rtlife Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    796
    Location:
    20 mins west of portland oregon
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    far from done but she sure looks good
    #20