Kawasaki KR1000 Endurance Replica

Fuel tank Stage 3

Rear Quarter panels and the start of the underside:

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Sand Bag and some proper hammering!

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Rear Panel shaped over an MDF former with a bit of hammering...

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R/H Rear Quarter and Rear panels finished:

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L/H Rear Quarter panel done...

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Detail - Chad shouts at me if I have gaps :oops:

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First 3 underside panels completed...

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Back for Stage 3 tacking and the commencement of the welds:

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Weld detail - pity they will be flattened off and painted :unsure:

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Chad finishing off the all the top panel welds:

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Fuel tank, the last leg...

Lower front marked out:


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Folded and in position:

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Lower rear panel - this was the trickiest panel due to the double curvature, with the tank being a different shape on each side - I had to guess as close as possible and sacrifice a sheet of aluminium as a test piece to see where it ended up, then adjust and re-fold a final sheet.

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The rear curved section was easier (for me at least) to do in 3 pieces, centre piece first:

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Then the 2 side pieces:

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Finished and fitting snuggly...

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The final piece of the jigsaw - the centre section is in place!

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Pingel fuel tap adapter fitted ready to weld in...

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Time for a trip to Hull yet again - battery box and seat support ready for welding too...

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More magic taking place:

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Tacked & then back home for final fitment checks to the frame:

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Fuel filler holes marked out and centre punched...

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And back to Chads for final welding:

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Rear tank strap hook in place:

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And the front:

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Fuel caps sat in place:

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Breather done - the tat anodising will probably be removed though :oops:

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One thing I didn't replicate was the wonky fitment / alignment of the bodywork :unsure:

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And managed to get it nicely in line :)

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That was a huge hurdle over for me with the build - thanks to furlough it was finished in a handful of months rather than years 👀
 
And dry build 1 is now complete - some pictures that make the whole project seem much closer to completion than it actually is - this is where progress slows to normal time again :whistle:
I threw a 1098R in some of the pics for scale :)


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Now stripped and the Engine and Belly Pan are away at Chads - the next major stage being the Ti Segmented Exhaust that he is making for the bike :love:

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TBC....
 
Well, back to normal pace now I've pretty much caught up with the story so far!

Monday I was over to Hull for Chad to do a few finishing touches to the frame:

This was an unsightly box section mount on the original down tubes and it had been bugging me for a while - so I chopped it off and bored the frame for tubes so I could use a triangular plate mount as per the original race bike...

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A few Weld Nuts were fitted to make assembly easier...

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Also added on the inside of the main frame rails in readiness for the wiring harness 'tubes' that I will be bolting in place for neatness:

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Weld nuts for the front fairing / headlight mounting bracket in place:

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And more weld nuts in non-accessible areas...

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Today I drilled and tapped the original steering stop and added alloy spacers to work at the correct level for the bottom yoke stops:

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If needed they can be swapped for larger diameter spacers for fine tuning but they are somewhere near...

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Meanwhile, far far away (about 40 miles anyhoo) Chad has been busy making progress on the Exhaust!!!

A bit of Chad jiggery-pokery and ingenuity was needed to 'engineer' the fit of the large 40mm tubing into the exhaust ports. The tubes will be held in place with springs.

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The first 40 sections of Titanium loveliness cut out for the downpipe top bends :love:

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Two tacked together :love::love:

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And then there was 4 :love::love::love::love:

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Well happy bunny here 🐰

A huge thanks and shout out to Chad! :)(y)
 
So, just been plodding along making a couple of stainless engine mount plates from 7mm thick 316 grade Stainless Plate.

Hand hewn and filed, then polished with Wet & Dry from 60 grit down to 1200. Need a bit more polishing and the large hole smoothing when my flapper wheels arrive, but nearly there.


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