RZ350 TZR 3XV Hybrid

[giron]

Ken

I believe all SP and SPR fenders are the same . I have two SP forks here. One is a 1992 and the other one is the 3XV-7 ( the black anodize forks). Brian rebuild both of them and he informed that the black anodize forks are better internally. I opted to change the forks for when I do my hybrid. I know the basic 3XV forks are smaller in diameter and the lower and upper tree are different.

[kpke]

12/7/23 EP3


I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat



It is well hung would you agree?




















https://youtu.be/drvYqdYnFa0?si=CkHyTcT4fm7bn7q5

[75RD350rider]

I concur

[kpke]

12/16/23 EP4

Some cleanup of some miscellaneous parts.














And a pre-mod meeting with Frame Maker.

[giron]

PM send

[kpke]

Thanks George.

12/17/23 EP5


I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat



After a meeting at the Professor’s house yesterday the boss puts his apprentice to work.

It begins looking like this.



Then goes on a weight loss program.







All done right?

No, needs a bit of grinding with a flap wheel. Never used one and boy what a great tool these flap wheels are.





All done right?

No, let’s do a little reverse spot facing on one of the magical machines in the Professor’s shop.



Left side on unit one.



And the left side on unit two.



Measure twice and cut once, right?



And a little trimming on the right side on unit one and two.









All done right?



No, let’s do some more magic on another giant machine.





All done right?



No, a final precision ream to make them holes perfect.



And back home safe and sound.

[kpke]

12/22/23 EP6




On a beautiful sunny December day, more grinding, sanding, filing, paint removal, at home in preparation for modifications.











12/23/23 EP6 continued

Back to Julian’s house where he exposes some motorcycle porn.



And the parallel project he is working on. With paparazzi cameramen all around recording the activities.







A well-deserved lunch break.



And back to work with a different rear end set up than what he is doing to mine.







A fixture used for locating and checking fitment of various components.









And back to the red frame.

[JonW]

Lovely to see these happening!

[Yamavarna]

Hey Ken, I have been watching this religiously on YouTube and for the life of me can’t figure why more people aren’t, are we really that narrow minded? Anyways, I am impressed at how easy it is to adapt the r6 tank to the rz, for those of us needing more rz tanks is this a viable alternative for a restomod? will the tank seat juncture remain similar? I would like to go done this road and I just need a little more guidance from someone who has been there.

[kpke]

Thanks for watching the channel. It's quite a bit of time editing the videos so I am glad one person is enjoying it. The mechanics of the seat to tank interface will be upcoming. Lots more custom metal fabrication and a custom tail. Stay tuned.

[kpke]

12/28/23 EP7

The tapered bearing races in the steering head require removal for powder coating the frame. I always put a nice little slot in the inside of the steering head above the races so that they can be removed after installation if required, BEFORE THEY ARE INSTALLED. This was not done on this frame after the ball bearing races were removed and before the tapered bearing races were installed.





I used my porting tool to very carefully grind behind the races 180 degrees apart just enough to get a drift in to knock them out.





Not having ground out the groove before the races were installed…I had to clamp the drift to keep it from slipping off the edge of the race.




Success. And after removal finished grinding proper race removal slots.

[Yamavarna]

https://i.imgur.com/TWxM8pM.jpg

Why would the subframe be pointed up in the air at a 45* angle?

[kpke]

Great question that I can't answer. This is Julian's handy work. He's been at it on that bike for a few more weekends so next time I see it I'll post photos.

[kpke]

12/30/23 EP8



Front wheel clean up. Removing the rotor bolts revealed a rather strange situation. While these bolts were clearly blue loctited where the threads would contact the wheel, they also had a very hard plastic material on them close to the head.





This material was extremely hard and difficult to remove. It needed to be removed because the bolts would not drive all the way back in without binding. I tried using a heat gun which helped but this was going to take hours. Next, I clamped a nut into the vice and drove the screws in and out until all of the plastic material was removed. Here are some samples when I was chipping it off manually.



I have never seen this much Loctite (or something) applied to a bolt.

The front wheel is now cleaned up and the rotors are back on the wheel ready for preliminary assembly.

[kpke]

1/6/24 EP9



It is time for some reassembly. Julian has a bunch of parts that he has designed and ordered enroute so this little project bike needs to become a roller.











There is no upper shock mount at the moment. So, the swingarm is flopping around. Do you see that custom component jammed between the swingarm and the frame? I designed that. And it is working quite well.