Final assembly!

Final assembly after painting has finally started! The frame is completely done just needs bits hanging off it now, just spent tonight putting new head bearings in, servicing the rear shocks and fitting uprated springs and fitted the swingarm, all bits fully serviced as I go along, the tickoff list is getting shorter and shorter very rapidly  :D  Now knackered half pissed and high on thinners used for cleaning bits, so all good

12v conversion Powerdyno

Also splashed out massively, well not really I finished paying CSA after 13 years and I managed to overpay by a month and a half, so in effect my ex missus has payed for a 6 to 12v/electronic ignition conversion from power dyno in germany, I only had to put £1.50 to it so it makes the deal sweet as f*** haha if only she knew, fitted it yesterday very high quality bit of kit, but not cheap as far as MZ bits are concerned, it cost more than the bike and engine rebuild alone  :o but is the icing on the cake. it benefits from being self energizing so Im putting a tiny 2.9 amp/hour battery under the seat, but could go battery-less if I got stuck with blown fuses in the middle of no where

Frame and swingarm done

Big progress this weekend, I finished stripping the frame, then decided to give it a coat of rust remover, would have been all good and well but the rust remover dried to a powdery surface that lifted as soon as you touched it, done use loctite rust treatment if you plan on just painting it on then overpainting. After a couple of hours I managed to scotchbrite it all off leaving a good surface to filler prime, this went on really well and with no reacting where I couldnt get to the rust treatment with the scotchbrite. This morning I rubbed all the frame with 400 wet and dry then prepped it for a coat of black enamel. I was dreading spraying this as Ive always brush painted it bofore and it runs just looking at it, so I turned the pressure down on the compressor and adjusted the tip to just give out a waft of paint with plenty of air and it sprayed a treat, I dont think Ill ever brush paint it again Im really pleased with the results, Id already hand painted the swingarm, side engine plates and main stand but wasnt happy with the brush strokes in it, so out came the trusty scotchbrite, gave them all a key and rubbing down the brushstrokes at the same time and these came up a treat as well. Very chuffed. To thin the enamel for spraying, just keep adding nitro celly thinners to it till it get to a watery consistency and stir well, dont leave it in the gun too long, if you have to make sure you stir the paint again or all the heavy enamel sinks to the bottom, and will spit out blobs of paint when you start spraying again. Major progress, its drying nicely now and then I can start on final build!

Tank Painted

Slow progress at the mo, sellin our house so been running around sorting that out, got paint on the tank, bit af colour sanding and polishing should come up perfect, no runs!

Base Coat

And with laquer

Still painting!

Still filler priming, tank is finally ready for top coat, its smooth as a babies bum at last, mz must have used loads of filler primer from the factory cause after sandblasting the stamp marks were really prominent and it took ages to blast, so after what seems like ages its finally ready to paint, bought the paint today its opal silver which is the closest you'll get to Norton silver, not too bigger flake in the metallic and close to the mz factory racing paint

Front wheel

The front brake on aa supa 5 is a weedy affair, the brake arm is enclosed inside the drum so this is unnecessarily short, I was going to machine the standard drum to allow a longer arm on the outside instead of inside, but I managed to bag another stafford classic bike show bargain. Its a Jawa 350 twin leading shoe front wheel and picked it up for a bargain £20 inc drum brake, sorted. Its such a good match that it even used the same front wheel bearings as the MZ and the ally rim looks near enough identical to the rear rim, result! The only thing is that it is about 10mm narrower that the MZ overall bearing surface, but at least its not too wide wich would have been a headache. So I mounted the wheel up in the forks,centralised it and measured for spacers. On the torque arm side of the drum it normally locates in a square in the fork leg, which the MZ one dosent have, so I need to get some 30mm x 3mm box section and make a torque arm mount, but this will double up as the spacer for the other side and should look pretty neat, so left spacer is done now its 5.15mm for the record leaving 4.65mm for the torque as side as its thicker. Looks great just the torque arm mount and arm to make and machine the top yolk down and thats the front end sorted.

 Left side centered and measured up

Right side temporary spacer washer put in and drum in place

to fabricate torque arm

Still going!

Second coat of filler primer now on waiting for it to harden, off to the paintshop to buy the colour and Ill update some pics when its painted. Also stripping the frame with a wire cup brush, then going to brush paint it with some satin black enamel over 1K brushable primer. Swingarm and main stand done.

Filler primer

First coat of paint finally on, wasn't planning to do any spraying today but seen as it was warm and sunny thought id take the opportunity, good to see the tinware all in one colour, major milestone achieved, but realised after i forgot the light cowl good excuse to lay some more 2k filler primer on the filled bits

Dragon Rally mode

Not exactly the cafe racer look haha but this is it in rally mode, perfect for my clubs rally, have a good laugh, panniers are only resting on for now, ive fabbed it up using any existing holes or bolts that were already there so when its off you will never be able to tell you had panniers on there lol

 

Quick Dry build

Done another quick dry build as my dad said he was going to pop over from Manchester for a visit, but as usual he promises but never turns up, ahh well nothing new there, given up with my family letting us down all my life glad Ive made my own great family away from them all haha! (moan moan lol)  Anyway its looking great!

Forks

Rebuilt the forks with new seals and oil, beadblasted the fork bottoms and they have come up a treat. Med has also made us some nylon bushes to mount the headlamp brackets on the fork legs, the rubbers were cutting up from the clipons and the bottom ally bushes tightening onto them and pushing them back inside the brackets, so the nylon bushes have done away with them completely and now is a lot better mounting than before and itsnt such a pain to take off the brakets when needed, it took me over half an hour to get the rubber ones to seat properly, also he made a nylon bush for the end of the twist throttle as the standard MZ has a bar end that pushes inside the throttle as well, so now have a proper working throttle, just need to make a spacer for the other side and some bar ends and thats the handlebars finished, also need to mill 5.25mm off the top of the top yolk, paint the yolks, and fit the new grip rubbers and that will be the forks, yolks and handlebars done. Next modify the drum brake to fit an external arm pull to give better braking than standard and fabricate a brake cooling duct, make a torque arm then beadblast the front wheel, paint the spokes and fit the new bearings and thats the whole front end done

Made a big to-do list up so I can start crossing things off and feel like Im getting somewhere

Before:-

After:-

Carb

Big thanks to Willis for coming up with this idea and to Joe to make it a reality, its the cold start side of the carb, it normally has a cable from the handlebars but their is no room for it on the clip-ons plus it neatens everything up on the bars and bike, its my favorite bit so far. It only looks a small piece but the lever had to be designed so that it lifted the standard plunger up high enough and have the right angle on it to stay open, also their is a small bronze bush that has a shoulder on it for the lever but also fits inside the existing cable hole and a small bar to replicate the cable with a turned little pin to connect it to the lever, loads of work for such a small piece!

Front end

Just a few pics from yesterday, sorted out my new compressor which involved pulling everything out of the garage so I can clear under the benches, good excuse for a clearup. Then fitted the clip on extenders and fork spacers, and got the throttle working, just need to mill the top yolk so I can bolt the stem down propelly, rebuild forks and sort out the front brake conversion and cable and thats the front end sorted.

Cheers Geoffo

Cheers for doing us some turning Geoffo! Saved me loads if time. The steel bits are clip on extensions and the alloy are spaces for my forks after adapting a new top yolk on, to space out the headlamp brackets. Fitting my new toy this afternoon can't wait

Visitor

One of my mates who we're going on the trip with popped round on his MZ ETZ that he's converted to an ISDT replica, done an amazing job as you can see. He tried mine out for size, god it looks small lol

Hooray got the other Tarozzi rearset

Friday, 9 September 2011

Just picked the other Tarozzi rearset up from a UK reseller guy who just lives up the road from me! Heres his website

http://www.discovolantemoto.co.uk/

What more of an excuse to go and have a blast up the road on the supermoto did I need just what I needed after doing 4 x 12 hour nights

Nighttime sandblasting

Sandblasted @ 3am this morning, all ready to weld fill and spray black