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Discussion Starter · #181 ·
Long overdue update time.

A few months back, I finally found the the lynch pin to a lot of my electrical problems, including burning reg/rec wires and busying starter solenoids after only a few starts. I cant remember how I stumbled on it - probably an RJ comment - but it turned out that my Chinese cheapo kill/start switch was not functioning as "intended". I replaced it with the true Motion Pro version and have been off to the races ever since.

Doing some pretty big stuff now that I have a little time on the weekends. List below with a picture or two, plenty more pictures to come as well.

1) Tail tidy (complete);I cut off the old rear portion and fabricated a nice new undertray portion that follows the fairing lines rather than sticking out like a sore thumb. I cut out a piece of plastic from a trash side fairing and used Plasti-Fix to bond it to the tray. Added a little body filler to smooth everything out, and painted the under tray flat black to freshen things up.

2) New Fairings; ordered a brand new set of fairings and I have all new OEM fittings to go with it. Very excited but I'll wait to talk color so I can post a reveal pic after they arrive. I plan to use Plastifix and pieces of my old fairings to reinforce all the tabs for the new fairings in order to ensure it's as strong as can be.

3) Bought the original headlight stay so I can mock up the fairing and headlight, mark some dimensions, and have the zzr mirror brackets welded to it. Will give it the OEM fit and finish but also allow me to keep my bird cage delete.

4) New chain/sprockets

5) New front and rear steel braided brake lines and a front master cylinder rebuild kit on the way.

6) Painting my tank and side fairings gloss black; trying out a catalyzed clear coat spray can so we'll see how that goes.

7) Clear Stompgrip tank grips and a clear Puig tank pad once the paint cures

8) Will get my rims stripped and powder-coated the next time I need a tire change.
 

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That does look much cleaner, Brandon. Can’t take credit for you chasing your demon down…. Cursing Chinesium would most likely have been Lloyd, lol.

Cheap switches, lousy connections, pot metal construction…. Yes, all of that.

looking forward to the reveal.

you should be coming up for orders soon….. any idea where you may be headed next?
 

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Discussion Starter · #183 ·
That does look much cleaner, Brandon. Can’t take credit for you chasing your demon down…. Cursing Chinesium would most likely have been Lloyd, lol.

Cheap switches, lousy connections, pot metal construction…. Yes, all of that.

looking forward to the reveal.

you should be coming up for orders soon….. any idea where you may be headed next?
I have a few packets in for some cool boi stuff, but otherwise I dont officially leave here till next September. I may know differently in a few months though.
 

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No reason to wait…. A friendly discussion with your detailer is not considered bad form. If your CO is happy with your work, it’s also a good idea to see what they think. Your next set of orders should not come as a surprise. Lead time is good, the more the better.
 

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Discussion Starter · #185 ·
No reason to wait…. A friendly discussion with your detailer is not considered bad form. If your CO is happy with your work, it’s also a good idea to see what they think. Your next set of orders should not come as a surprise. Lead time is good, the more the better.
Oh no, my CoC is super cool about everything. I have a packet just about ready to submit for reversion to Warrant. Everybody has been in my corner so I can't ask for much more.
 

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Academy grad to Warrant would have stigma in the USN…. Not many CWO at all; less I think than LDOs. It may be different in the Army. I’m guessing you’re not thinking of making it a career—- before you demote yourself, it may be worth considering changing branches. If you want to fly attack helicopters, the Army is not the only game in town.

the helicopter community in the USMC will remain robust H53 and V22, smaller H1 community, the missions flown in the USN are evolving with damn near everything carrying ordnance now.

Many H60, some V22
 

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Discussion Starter · #187 ·
Academy grad to Warrant would have stigma in the USN…. Not many CWO at all; less I think than LDOs. It may be different in the Army. I’m guessing you’re not thinking of making it a career—- before you demote yourself, it may be worth considering changing branches. If you want to fly attack helicopters, the Army is not the only game in town.

the helicopter community in the USMC will remain robust H53 and V22, smaller H1 community, the missions flown in the USN are evolving with damn near everything carrying ordnance now.

Many H60, some V22
Not much any stigma on the Army side anymore. Doesn't sideline me for anything and I'm neither here nor there on staying in long term.
 

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All new brake lines and front master cylinder rebuild kit
Honestly I haven’t been convinced that the pivots on the ends of the lines are a good idea. More moving parts mean more potential points of ingress for moisture…. New lines trip old ones, and rebuilt MC on top of that…. Good stuff regardless.
 

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Discussion Starter · #191 ·
Honestly I haven’t been convinced that the pivots on the ends of the lines are a good idea. More moving parts mean more potential points of ingress for moisture…. New lines trip old ones, and rebuilt MC on top of that…. Good stuff regardless.
I guess we'll see how the lines hold up with time.

Getting a bunch of parts/tools in soon. Long story short, I bought an A/C TIG welder and will be teaching myself how to weld aluminum. The tool and skill will be worth every penny. Also, Argon gas is kinda expensive lmao.
 

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Discussion Starter · #192 ·
So, obviously its been a hot sec now since the last post. Turns out my welder got lost in shipping so I had to re-order. I have a Primeweld TIG225X inbound now with a CK17 torch and the like. A bit more expensive than the one I originally ordered, but after some thought it made much more sense to go with the welder with a better duty cycle and much higher ratings in its class.

So, I have a substantial crack in my frame. It's located on the top left side and does not have any mounts or weight baring items near it. Assuming it was a stress crack from a long time ago. That said, I used a teardrop shaped bit to create a channel where the crack is and drilled out the ends where the crack stops. I have a lot of practice to do with my welder once it arrives but hopefully soon I'll be able to weld up the crack.

I'm not looking to grind the finish down smooth, I figure the more material in that spot the better. If I can manage to make decent looking welds, I'm going to try to "weave" the weld pool to widen/thicken it. We'll see. I need to clean it really well, I have brand new steel bristle brushes to knock off any extra crud before I start. I'll get pictures of the before and after; may still be a week or two before my welder finally arrives but I'm looking forward to the challenge.

Unrelated to the frame but related to the welder, I also just got in a new (to me) gauge cluster/headlight stay. What I plan to do is cut off the zzr fairing stay mirror brackets and weld them (stick weld) to the OE cluster stay so that the cluster is back to OE fitment but I can still get away with not having the ugly bird-cage.

Also servicing my front forks again due to an oil leak I found. Turns out the damper on my right fork became detached from the adjuster which was super weird but I'm glad I found that when I took it apart.


Question for anyone still reading; has anyone heard or know what newer year model swing-arms might fit on a 96? I'd rather not mess with spacing the front sprocket so if a swap involves anything other than a longer chain, I'll leave it as-is.

More to follow.
 

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The parts compatibility thread in the technical section should give you candidate swing arms. It’s more aligned to models near your vintage than more current.

Good to hear you drilled out the ends of the crack…. I learned about that roughly ‘81, as the same thing applies to cast iron pipes aboard ship.
 

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Discussion Starter · #194 ·
The parts compatibility thread in the technical section should give you candidate swing arms. It’s more aligned to models near your vintage than more current.

Good to hear you drilled out the ends of the crack…. I learned about that roughly ‘81, as the same thing applies to cast iron pipes aboard ship.
I may not have read far enough down; from what I saw that thread only mentioned the G model and newer but perhaps the swingarms are identical. To the forums depths I dive.
 

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View attachment 112628
The garage is super messy right now, but I've got my little welding corner all set up to start practicing for the main event.
I think I retired from the navy with a portable work mate bench, a circular saw, and the craftsman tools I had purchased to rebuild my Triumph, before I blew it up….. you’re a few steps of where I was at a similar point in a career.
 

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Discussion Starter · #198 ·
Just a minor taste of what's to come. Tomorrow starts a long weekend and I plan on reinforcing all the fairings, finishing my fork oil and seal replacement, and hopefully welding my frame (or getting a lot if practice in). I need to fix the crack and I also plan to weld in a new, appropriately sized steering stop.
Automotive design Automotive tire Vehicle Fender Thigh

Window Couch Window blind Comfort studio couch
 

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Discussion Starter · #199 · (Edited)
And yes, I have a boat load of Kawasaki/ZX6R stickers to badge this thing up. I also have stickers from every brand that ever took my money in exchange for parts - not sure if I make it look like I'm sponsored because it's funny or leave it be...
 

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Your frame is all steel, right? That's so much more forgiving....

I too have a drawer full of stickers for stuff that went on the bike over the years. None o fthem have ever been put on the bike. If I crash, I want to be able to blame the bike, not the trick parts I may or may not have purchased.
 
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