KZ650 Sleeper Build (KZ1000 engine transplant)

If it's the idler at the top of the head, that's the easy one to change.  As you know, the two lower idlers are a little more work to change...

I had the rubber on one of those kick the bucket at 11k rpm this last year. chunks all over the oil pan - I bought 2 of the new liska ones but if the old ones are rebuildable/reusuable id keep em for spares -

I got out in the garage today and got all the holes drilled, then I started milling the main slot for the sprocket.

Its slow going on the mini mill

Injected wrote:

I got out in the garage today and got all the holes drilled, then I started milling the main slot for the sprocket.

Its slow going on the mini mill

We work with what we have

Yes, its just frustrating taking 1/32" passes when I need to cut away +1-1/2" but it will get done. It was 12C in there so not too horrible, better than a visit to the dentist

This is where I stopped for the day.

 
 

It got cold and windy overnight with trace snow so the garage is now 7C. Its OK in there as I can't see my breath, once I see my breath and my nose gets cold its time to re-evaluate if I need to be out there or not.

Today I did put some time in and milled that slot down to the two holes at the clamp edge. I now need to change the cutter so I can go right down to the bottom of the holes. Then I need to go back to that 1/2" cutter to widen the slot to the finish size of .590" (center dowel length)

It all takes longer on a manual machine with no DRO but its coming along as anticipated.

I stopped early today as I had a visitor and the whiskey came out

Got out there today for a short while to continue cutting that slot.

Used the 1/2" end mill to go as low as possible on center then switched to a 5/16" to go to the bottom of the radii holes.

 

Switched back to a 1/2" end mill to clean out to the finished width of .590" and slid the center pin in which is .589" long. This mill is small but its pretty accurate, and good enough to make these kinds of parts.

 

There is a little witness line across the length where I had to put the cutter down in two steps but it clears the pin OD. The 1/2" end mill I have was not long enough to machine it in one pass. 

I will see if I can get some more work done before we get a dumping of snow.

 

Every time I go out to work its colder, 6C today inside and expecting snow tonight, possibly 6 inches or more.

It took quite a while to mill out the inside pocket, and my 1/2" end mill was just long enough.

 

 

Next setup is at a 45 degree tip and have a 1/4" end mill mounted to cut away some of that material left on both ends of the slot to clear for the idler sprocket. Very light cuts expected so the setup should suffice but realistically I could do the same thing with a 1/4" carbide in my Dremel tool.

 

We did get 6" of snow over 2 days, and the temperature in the garage (unheated) is hovering around 4C so I can see my breath when in there.

Hoping to finish machining this bracket soon but there are other jobs around the house that keep getting in the way.

Once I get back on it I think I will wait till milder weather to swap out my stator.

I was able to get out in the garage today for a short time so I did the angle cuts for the sprocket clearance then cut the top slot where the sprocket teeth stuck thru.

 

Had it assembled in there from one side and it spins just fine with no binding. A few mistakes along the way but its functional.

Will continue with machining it if nothing else gets in the way, the wife keeps on finding stuff for me to do.

Got out in the garage to get some work done, it was 2C in there but forged on. 

A bit of a funky setup after trying to cut it with a end mill, which was too slow. 

 

The 2" face mill gave better results, but had to bridge the slot gap to stop it yapping and run a C clamp to make it rigid. 

Stopped short of where I need to be as there is another job that needs my attention. In no rush to get it done so I will get back on it when time permits.
 

After a couple of days of snow (about 8") it was mild and sunny today so I did a bit more milling but quit just a bit short of being able to take it out of the vice. My feet got cold so it was time for a whiskey

I did buy this extra 650 idler off Ebay as it was listed for $3, but with shipping and exchange it came to about $33 Canadian, still a bargain and will be "rebuilt" with billet center.

 

Nothing going on tomorrow so I may be able to finish up on this bracket.