TOPIC:

Started work on the frame bracing.


Headstock first.
Before and after removing horrid factory bracketry


Frame under boxed in bracing has never seen paint and was full of rust


New improved bracing plates. (3mm -(1/8th inch)- steel sheet from old bus stop )
These will be seen as fuel tank will sit on the top frame tubes so need to look the part



Several hours and burnt fingers later.









Rest of the frame will get the same treatment in due course.

Excellent work.
Tally Ho

youve got my undevided attention!

Another section of rust harbouring bracketry bites the dust


To be replaced by more swiss cheesed bus stop




This also provides space to hide a reg/rec in case i don't accuire a magneto or fit a belt drive alternator

really nice work there zed thanks for sharing the pics.
keep us posted,

leon

I'm following this with interest, especially as I'm modifying the frame on my 750 turbo and using ZX10R forks.

I'm surprised at the differences between the Zephyr frame and the old 750 frame. The Zephyr frame is much chunkier. The 1100 motor would go in the 650/750 frame without removing the downtubes, but you couldn't get the cam cover off . I'm not against removing the downtubes in principle, it looks nice.

I really like this project, ile be watching it closely

Yeah i've done the 650/1000 thing a couple of times but it's not really worth the hassle.
Couldn't believe that they hid a frame like this under all that bland bodywork.
As soon as i saw it i knew it had to be done, Didn't plan on loosing the frame tubes though but that's projects for you, They always turn into something bigger (and better ?)
It is a tight fit, 2mm clearance front and back , Just enough to squeeze in some paint but the head etc can be removed in situ and just pushing it around it FEELS right,
The frame hugs the motor and it's hard to tell by the pic's but it is small, only 5 inch between the cases and the front tyre so i'll have to be inventive with the exhaust to avoid restricting the 1428 block whilst keeping it all in proportion.
Fingers crossed .

hocbj23 wrote:

...Zundapp built a lovely 250 two stroke with the motor as a stressed member.There was no front downtube at all.As best I can remember,the motor was "slung" underneath the top tubes and attached there plus at or near the rear swing arm.Looked a little funky but very rigid and handled very well....

Evokes fond memories.

Good Fortune!

take a look at any old harley sprint or even a 750 to 1100 virago they used the engine as a stressed member. lots of other examples makes it way easier to pull the engine which is cool when your building crazy hot rods.

timebomb33 wrote:

take a look at any old harley sprint or even a 750 to 1100 virago they used the engine as a stressed member. lots of other examples makes it way easier to pull the engine which is cool when your building crazy hot rods.

i just love the way u redid the gussets. u managed to blend form and function perfectly, and came out with a lighter, and stronger frame to boot.
Way to go man.

More welding and bus stop butchery today .

Got the subframe mounts done and some stainless rose joints fitted waiting for an ally subframe

Don't know if they will go on the inside or the outside of the mounts till i start playing about..




The threaded spacers between the plates are stepped and a press fit as well as being welded


Outer top plates follow the lines of the top frame tube so that they will blend with the fuel tank ( once i've made it ) and double as an external brace for that bend in the frame (Every little helps )



Couldn't get a decent pic under the flourecent lighting and it was raining outside .