My RZ350 Project in Austin, TX
Moderator: rztom
My RZ350 Project in Austin, TX
I am a big fan of 2 strokes as my hero's Kenny Roberts and Freddie Spencer rode them to Championships in the 80's.
I came to realize early on that this bike had potential. But the brakes on the RZ seemed weak and it suffered from frame flex. So I upgraded the bike with a FZ600 box swingarm and Fox Twin Clicker shock, FZR600 front end, wheels and brakes. Also Rask rear sets and Airtech solo seat cowling. I was able to fit a 150/60 rear tire with the help of an offset countershaft sprocket from RZ's unlimited. I did this part of my build in 2001 just before having my Daughter, which put this project on hold until earlier this year.
I came to realize early on that this bike had potential. But the brakes on the RZ seemed weak and it suffered from frame flex. So I upgraded the bike with a FZ600 box swingarm and Fox Twin Clicker shock, FZR600 front end, wheels and brakes. Also Rask rear sets and Airtech solo seat cowling. I was able to fit a 150/60 rear tire with the help of an offset countershaft sprocket from RZ's unlimited. I did this part of my build in 2001 just before having my Daughter, which put this project on hold until earlier this year.
Last edited by mixalive on Sun Jul 21, 2019 3:44 pm, edited 3 times in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Fast forward to 2015, I began researching different frame bracing configurations. I chose a system of braces based on a 90 degree lattice configuration off this site.
Now, I am a pretty good mechanic and novice fabricator. But I am not a welder. So I am fabricating all my frame mods and tacking it up for an expert tig welder. Here is an image of the bracing. I used 7/8 OD X .065 wall 1020 DOM A513 Round Steel. Because of the contour of the frame, the lower bar shown is bent inward 15 degrees at 1L-3L.
Now, I am a pretty good mechanic and novice fabricator. But I am not a welder. So I am fabricating all my frame mods and tacking it up for an expert tig welder. Here is an image of the bracing. I used 7/8 OD X .065 wall 1020 DOM A513 Round Steel. Because of the contour of the frame, the lower bar shown is bent inward 15 degrees at 1L-3L.
Last edited by mixalive on Sun Jul 21, 2019 3:48 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
I am installing an FZR400 fairing, mid, lower, instruments on this bike, so I needed to create mounts for it all. I also found the the fork stop did not mate well with the bottom tree so I had to address this prior to mounting the fairing mount. Also the FZR600 top tree switch location didn't mate up with the steering lock. I really don't care about a steering lock so much but decided to deal with this at the same time. Here are images of the fairing mount.
Last edited by mixalive on Sun Jul 21, 2019 4:00 pm, edited 4 times in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Next step was to create mounts for the mid fairing. I fabricated some brackets using 1/8 steel and some of that left over 7/8 tubing and used stock FZR400 brackets. I did this on Labor Day 2015.
Last edited by mixalive on Sun Jul 21, 2019 4:06 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
I have been working on finishing the fairing mid and lower brackets. Lots of fab, lots of fitting. But it is coming along. The first image is the front lower fairing frame stays made out of 1"x1" steel tubing, then tack welded to the frame. The second is the mock up with the lower fairing. I drilled it and welded a 6mm nut and moved to the next bracket.
Last edited by mixalive on Sun Jul 21, 2019 4:12 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Next is the rear lower bracket. I built two stays from 3/4" x 3/4" square tube, welded a nut on the back and tack welded to the frame. I made a bracket similar to the factory FZR brackets by shaving off of the 1"x1" square tube. Check out the FZR kickstand.
Last edited by mixalive on Sun Jul 21, 2019 4:20 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
The last set of fairing brackets. It stabilizes the rear of the mid fairing to the frame top tube.
Last edited by mixalive on Sun Jul 21, 2019 4:27 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
The air box on an RZ incorporates the battery box. To eliminate the air box, I cut the battery box off of it. The battery box gets its front mount from the air box. With the air box gone, I built a bracket to stabilize the front of the battery box.
Last edited by mixalive on Sun Jul 21, 2019 4:37 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Here is the fabrication I made for the damper bracket and the shock reservoir. The reservoir brackets came from a 4WD shop.
Last edited by mixalive on Sun Jul 21, 2019 5:24 pm, edited 2 times in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Here are the final fairing brackets, electronics brackets and cross member gusset braces.
Last edited by mixalive on Sun Jul 21, 2019 5:09 pm, edited 3 times in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
I created a path for the left throttle cable to clear the frame.
Last edited by mixalive on Sun Jul 21, 2019 5:27 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
Here are a few images of the frame before it goes out to the welder.
Last edited by mixalive on Sun Jul 21, 2019 5:33 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
Re: My RZ350 Project in Austin, TX
I am sending the swingarm out with the frame to have the welder complete my spool install.
Last edited by mixalive on Sun Jul 21, 2019 5:36 pm, edited 1 time in total.
RZ350 with FZ600 swingarm, FZR600 wheels, front end and FZR400 bodywork.
- TommyPettersen
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Re: My RZ350 Project in Austin, TX
That is some really nice fabrication work. Will be interesting to see how it turns out...