Well progress is shown sometimes in baby steps. Here are some that I finished the last couple of days. My friends from Mountain States Automation have been helping me with some machining and welding.
Ok I finished this last week. But here is a picture of a newer model ZX6E crank setup in ZX6D cases. I had to change cranks because in the D Model the big ends were 36mm and the set of rods I got (for next to nothing) fit a newer model crank which the big ends were 33 mm. I fitted the newer crank with a new set of Carrillo rods and new main bearings across the board. I am waiting on a set of pistons from JE Pistons. If you happen to need some pistons done these guys are great... Well worth your time to inquire...
Next I got a different intercooler. The issue with that was the end inlets were a massive 3" diameter. So what we did was milled off the end plate from outside to inside, made new plates and cut new 2" pipes and welded in place. So now 2" inlets instead of 3" inlets and this is the finished product.
This is a before picture:
This is a after picture.
Next I wanted to show the swingarm extensions they made from a block of aluminum. The reduced section of the extension fits into the stock swingarm and it mates up with a lip that fits flush against the stock swingarm then bolts thru the top of the stock bolt holes. This holds the swingarm extension into place and a single bolt goes thru to hold in the existing swingarm position, center. The other end they machined out an exact replica of what the inside of the stock swingarm looked like where the adjuster mechanism fitted. This is so we can utilize the stock adjuster. These give me 4"-6" extension.
Next is we have the new coil setup mounted in place. We used the mounting holes on the water pipe coming off the head. Used a stainless piece and just used a metal brake to give a 60 degree bend. Tapped holes to accept the coils and there you have the finished product. You also see the MXL dash unit installed.
Other things that have been done that is not worthy of pictures. Is I purchased a complete set of ceramic bearings. I installed one into the sprocket hub, and I am waiting on the frame, swingarm and wheels to get back to install the rest of the bearings.
Almost have the turbo finished, we took out the internal wastegate and we are in process of installing and external wastegate. By doing to I needed to divide the two chambers from wastegate side and exhaust side. Took some thinking to get this done. The exhaust housing is made from cast iron.. It was suggested NOT to weld a plate into the housing. So we threw around a bunch of different ideas. We finally decided on one and almost finshed with it, they have some milling to do yet and ill show the finished product when done.
Jon