Big Zed Build Thread......
Discussion
KTMboy said:
As suspected plenty of sludge in the bottom of the sump, plenty of lumps of old gasket and silicone but luckily nothing metallic....
15 mins in the parts washer soon cleaned it up..... stripped the oil pump and chucked that in too....
So the plan is to enamel the main engine casing aluminium silver and then all the separate engine casings, the block, head and valve cover a nice black.... with new gaskets all round.....
How do you apply the Enamel out of interest?15 mins in the parts washer soon cleaned it up..... stripped the oil pump and chucked that in too....
So the plan is to enamel the main engine casing aluminium silver and then all the separate engine casings, the block, head and valve cover a nice black.... with new gaskets all round.....
Awesome project you have going on there!
Edited by s1dew1nd3r on Friday 1st May 00:43
Installed pistons today....
Didn’t go exactly go to plan...first of all I managed to shear off the head of the screw that holds the cam chain guide in the cylinder... luckily it eazy-outed ok.... and then I really struggled to get the 3rd and 4th pistons in to the cylinder....... got there in the end .... after the wife rather surprisingly had a good idea.
Didn’t go exactly go to plan...first of all I managed to shear off the head of the screw that holds the cam chain guide in the cylinder... luckily it eazy-outed ok.... and then I really struggled to get the 3rd and 4th pistons in to the cylinder....... got there in the end .... after the wife rather surprisingly had a good idea.
Anyone come across this Z1 build?
https://www.youtube.com/watch?v=GhrLg6mZQIo
Before you bolt it all together, maybe you should get the hacksaw and Tig out !
https://www.youtube.com/watch?v=GhrLg6mZQIo
Before you bolt it all together, maybe you should get the hacksaw and Tig out !
Got my own project Zed 1100 cases back from Camcoat last week (had high temp ceramic finish), so the engine build could begin. Didn't take long to find a problem, which wasn't noticed when the cases were oily... a not unusual problem so I'm told... so took the case to my mate Geoff the welder, who ground down the damaged area, then rebuild it with weld. Next step is to machine it back to standard. I'm told 'its not a problem', but we'll see..
On to the head today as it was miserable outside....
The original head had too many broken fins so picked one up from eBay
|https://thumbsnap.com/DGp2Ck3X[/url]
It’s in pretty nice condition. I blanked off the weird emissions holes so I can use a earlier model cam cover and then set about lapping in the valves. Inlet valve and seats were in good shape, but couldn’t get the exhaust valves to seat well, luckily I had some spares from the old head which bedded in very nicely.....
[url]
The original head had too many broken fins so picked one up from eBay
|https://thumbsnap.com/DGp2Ck3X[/url]It’s in pretty nice condition. I blanked off the weird emissions holes so I can use a earlier model cam cover and then set about lapping in the valves. Inlet valve and seats were in good shape, but couldn’t get the exhaust valves to seat well, luckily I had some spares from the old head which bedded in very nicely.....
[url]b
ks, went to fit the cams in the head today and the threads for number 1 and 2 cam carriers are all buggered.... and to make matters worse some of them already had inserts in which just fell apart or span in the hole......there is no worse feeling than a bolt just turning and turning when you are working on a complex casting like a head ... but when you get 8 on the trot .....
Going to try cleaning out the holes, retapping and fitting 3D helicoils with 10mm longer bolts and hopefully the extra length will give enough purchase to hold
If not, then it’s drill everything out to take a M8 thread and use M8 bolts. There’s plenty of clearance to go M8 but I’ll have to make some small pegs to ensure the carriers stay aligned .... good job I kept the old head so I can do some “prototyping”.
The joy of working on a 40 year old, 10 owner motorcycle...
ks, went to fit the cams in the head today and the threads for number 1 and 2 cam carriers are all buggered.... and to make matters worse some of them already had inserts in which just fell apart or span in the hole......there is no worse feeling than a bolt just turning and turning when you are working on a complex casting like a head ... but when you get 8 on the trot .....Going to try cleaning out the holes, retapping and fitting 3D helicoils with 10mm longer bolts and hopefully the extra length will give enough purchase to hold
If not, then it’s drill everything out to take a M8 thread and use M8 bolts. There’s plenty of clearance to go M8 but I’ll have to make some small pegs to ensure the carriers stay aligned .... good job I kept the old head so I can do some “prototyping”.
The joy of working on a 40 year old, 10 owner motorcycle...
If M6 helicoils have already been used in some of the holes you can't drill out to M8. The OD of an M6 helicoil is about 7.25 and the tapping drill size for an M8 fine thread is only 7.00 so your hole is already slightly bigger, mashed up and probably not round. To get anywhere near a decent M8 thread easily with the holes you have would be to go bigger and insert M8 helicoils/time-serts if you have the room.
Personally I'd be looking at other options.
Personally I'd be looking at other options.
Edited by mygoldfishbowl on Tuesday 5th May 02:23
mygoldfishbowl said:
If M6 helicoils have already been used in some of the holes you can't drill out to M8. The OD of an M6 helicoil is about 7.25 and the tapping drill size for an M8 fine thread is only 7.00 so your hole is already slightly bigger, mashed up and probably not round. To get anywhere near a decent M8 thread easily with the holes you have would be to go bigger and insert M8 helicoils/time-serts if you have the room.
Personally I'd be looking at other options.
Just drilled out a hole ready for a new M6 helicoil. Perfect at 6.2mm. Would easily go to 7.2mm for a M8 fine if necessary, but would prefer to stick with M6.Personally I'd be looking at other options.
Edited by mygoldfishbowl on Tuesday 5th May 02:23
Only the obvious I'm afraid. Expensive machining, plugging, welding, etc or another head but obviously neither option will be cheap. Personally speaking I'd get a couple of quotes on machining and then probably end up buying another head.
I have been in the same sorts of situation before and I do feel your pain.
I have been in the same sorts of situation before and I do feel your pain.
KTMboy said:
Just drilled out a hole ready for a new M6 helicoil. Perfect at 6.2mm. Would easily go to 7.2mm for a M8 fine if necessary, but would prefer to stick with M6.
From what you said earlier I thought some had been helicoled previously and span at some point? You can't drill a 6.2 hole in a 7.25+ hole. What am I missing.
Edit, Re read your other post and am now thinking your 6.2 hole is a new hole as you've gone deeper into the head?
Edited by mygoldfishbowl on Tuesday 5th May 12:02
mygoldfishbowl said:
KTMboy said:
Just drilled out a hole ready for a new M6 helicoil. Perfect at 6.2mm. Would easily go to 7.2mm for a M8 fine if necessary, but would prefer to stick with M6.
From what you said earlier I thought some had been helicoled previously and span at some point? You can't drill a 6.2 hole in a 7.25+ hole. What am I missing.
Edit, Re read your other post and am now thinking your 6.2 hole is a new hole as you've gone deeper into the head?
Edited by mygoldfishbowl on Tuesday 5th May 12:02
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