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Stunning job Howard, as an aside (bit late now  ) when we used to apply dealer fit decals to cars we found if we sprayed the panel with a mist of very diluted soapy water (washing up liquid/dish soap) it allowed you to pull the decal if necessary without stretching it and it made it easy to rub out any bubbles with a rubber blade. Just need to make sure you leave it long enough to dry out before clear coat

Thanks Wookie! 

A period Kerker megaphone would really complete my "tribute" to the legendary machine, but they are rare and crazy expensive now. I see one listed on Ebay for $1060 excluding shipping! 

So, I modeled one (using some assumed sizes) in Solidworks. If anyone has some basic dimensions, I would really appreciate it.

Having had a bit of experience designing and fabricating 2-stroke expansion chambers, I might just give this a shot...
and "roll my own", so to speak.

 

H.

Just for interest, here are the parts that I have designed and made for this build, using various processes, from laser cutting to 3D printing.



If anyone needs my files / designs, just ask!

H.

Looks like time to update your Avatar 

I think you're right Wookie !

Done!

All of the parts you have made look great.  My hat so to speak it off to your work.  As to making a Kerker there is an old long post here on exhaust that does have some measurements within it.  Here is a link to the list kzrider.com/forum/2-engine/271747-header-pics?start=48 that has listed the measurements for a Kerker street pipe.

Thank-you @gd4now, that's exactly what I need!

H.

I am glad to hear it could be of help.  There is a lot of interesting things/data/knowledge on this site, some of which takes some search to find. 

I forgot? (can’t say how that was even possible) to apply the Lawson Replica “badge” decal to the top of the tank!!!
And what would a replica be without it????
So, I had no option but to “key” the entire tank with a Scotch-brite pad, to make ready for the decal and MORE clear-coat.

I agonised over the position of that emblem….
There are numerous pictures of ELR tanks online, but none seem to show the emblem at a consistent distance from the gas-cap.
I ended up using a picture of a tank, that was taken at the recent Mecum auction, and deduced a measurement … 28.5mm form the cap.
I applied the decal and then another 3 coats of 2K clear.



I also rebuilt the gas-cap:
Sand-blasted the aluminium / pewter gubbins, which made them look like new!
3 coats of 2K gloss black on the flap, and a new 3D printed gas seal.
I’m happy with the result.



Also, I found a front fork brace on Ebay, for $40, which I thought was a steal!
Polished with AutoSol, looks quite fab. me thinks!



H.

Update:

I needed to make a tool tray, to replicate what that the J and R models had.
A few on-line pictures of the genuine tool tray provided "form" and "scale" reference, and here is the design I came up with, and 3D printed...



Wiring "clean-up" was required, as there were a couple of un-used connectors from the fuel injection system.

See this pic of what it looked like under the seat / tank, on the day I took delivery... 



Here is what it looks like under the seat now...







Also, I was chasing a fuel leak from 2 float bowls...
I 3D printed new gaskets and also the choke plunger "tip-seals" (Mikuni BS34)
Also, I fit new "rubber tipped" fuel needles and seats, new main and pilot jets (Ebay) which had been severely butchered by the philistine that was in there before me!
Pilot screws 3 turns out.

She starts easily now, especialy in sub-zero temperature, on full choke (which was a struggle beforehand)
Once warmed up, she idles reliably at 1100 rpm.
Carburation is now better that it has ever been, no more "popping" on overrun, with fat mid-range pull, all the way to 9000.

I'ts winter here now, but I ride every day! 

H.
 

Great work as always Howard - now stop dithering my SA buddy and get the details over to me 

Yessir!