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Thread: Kawasaki zxr-E

              
   
   
  1. #51
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    Hi Flo
    I like the braces but my one observation is you should have some spacer tube over that long bolt so that you can clamp it with some force to stiffen the brace up. The bolt will just flex or even just move with the length and leverage of it. I suspect you might know this already, but I love your build and wanted to ensure you didn't miss anything.

    Fantastic work so far, look forward to the first test run!

    Cheers
    Tyler

  2. #52
    Senior Member flo's Avatar
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    Hi,
    yes thats all planned, want to sleeve it with some tube but i am still missing the right sized washers. Thanks for your concerns and kind words

    flo

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  4. #53
    Senior Member flo's Avatar
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    Hi,

    Got the braces done

    20210313_171806 (2).jpg

    another cutout was needed in the tank in order to make room for the chargers plugs
    20210313_171815 (2).jpg

    Then it was time to do some finishing touches for a change
    20210314_144422 (2).jpg20210314_144413 (2).jpg20210314_144922 (2).jpg20210314_144431 (2).jpg

    Hard to get a meaningfull pic on the aluminum surfaces
    20210314_145457 (2).jpg

    stay tuned

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  6. #54
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    Quote Originally Posted by flo View Post
    Hi,

    Hard to get a meaningfull pic on the aluminum surfaces
    20210314_145457 (2).jpg
    It's all crackin' work but that - that is just exquisite!

  7. #55
    Senior Member flo's Avatar
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    HI
    thx spoonman

    progress gets less visible, but there is some
    charger holders gone from 180 gr. to 118 gr. - when i mentioned a diet i meant it
    20210317_103228 (2).jpg

    also updated the wiring circuit, dc-dc and relay updated.
    Indicators and break lights active as soon key is turned on, lights come on per switch..
    Strom5.jpg

    opened all handlebar switches and ripped out unnecessary cables, saving another 95 gr.
    so its all new plugs and ready to be connected.
    hope to have all the blinky and beepy things done by this weekend

    stay tuned

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  9. #56
    Senior Member flo's Avatar
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    Blinky, beepy bits done

    Hi
    got all lights, horn cabled.
    Works perfectly so it seems my wiring diagram being free of faults
    20210321_104818 (2).jpg

    wrapped the loom and cleaned up the cockpit
    20210321_110050 (2).jpg

    Once more time for some finishing touches.
    still need either a bit more notching to completely close ,or, which is what i contemplate re route the controller wires some ..
    otherwise looks quite unobstrusive to me

    20210321_172944 (2).jpg

    will get a cover of course
    20210321_173004 (2).jpg

    To do list getting shorter..

    stay tuned

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  11. #57
    Senior Member flo's Avatar
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    Hi
    days getting longer means i can put in 1 or 2 hrs after work.
    So just before it was getting to dark to take pics, the re-routed cables and some more notching ensured the fairings close completely.

    front of fairing
    20210323_180902 (2).jpg

    sideview looks like a big cutout but actually the controller and cables stick out just 4cm underneath.
    Cover will need to be ab out 7 cm high at the sides, 4 cm at the front...
    Will tackle that by tomorrow
    20210323_181425 (2).jpg

    stay tuned

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  13. #58
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    Quote Originally Posted by flo View Post
    Hi
    days getting longer means i can put in 1 or 2 hrs after work.
    So just before it was getting to dark to take pics, the re-routed cables and some more notching ensured the fairings close completely.

    front of fairing
    20210323_180902 (2).jpg

    sideview looks like a big cutout but actually the controller and cables stick out just 4cm underneath.
    Cover will need to be ab out 7 cm high at the sides, 4 cm at the front...
    Will tackle that by tomorrow
    20210323_181425 (2).jpg

    stay tuned
    Hi Flo
    Looking good. I wonder only if the controller is protected enough from say speed humps or bumps etc hitting it? Will the cover be structural somehow?

    Cheers
    Tyler

  14. #59
    Senior Member flo's Avatar
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    two steps forward, one step back

    Hi
    been a while.
    have the bikes cables done, got it inspected by my buddy robert, who promptly found a mistake in my diagram, solving the the dc show "on" but not charging.
    detail:the switched side (key on dc/dc) needs to see 100 volts too.
    attached an updated version of my diagram:
    Strom 6.jpg


    @ Tylerwatts

    no need to worry, eventhough i did cut the first cover to wrong size.

    second part already milled up (again), covered in packing tape (again)
    20210330_164439.jpg

    and curing in vacuum bag once more.
    20210330_190501.jpg

    Layup from outside
    4 layers glass 105gr Aero quality
    1 Layer kevlar 110gr to keep it from splintering
    1 Layer 160 gr glass (kevlar always needs to be covered in glass)
    1 Layer Lantor coremat ( sandwich material)
    4 Layers glass 105 gr Aero quality

    12Hrs vacuum, 15 hrs warm curing in my temper box-

    Stay tuned
    Last edited by flo; 30 March 2021 at 1255.

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  16. #60
    Senior Member flo's Avatar
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    Hi
    reprogrammed the Kelly Controller today and had the motor turning first try

    primary drive connected, thankfully cad files were spot on, chain thight but not too much.
    20210401_142216.jpg


    Vid shows the starting sequence:
    https://www.youtube.com/watch?v=cDjgEopT9e0

    put all fairings on ( minus the controlelr cover down below) and got it on the scales:

    99 KG up front , 91 on back, so 190 kg or 422 pound some 5 kg more than ice. , my hope had been equal weight..

    On the bright side:
    Testrun tomorrow

    stay tuned
    Last edited by flo; 01 April 2021 at 1212.

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