~ Where I finally get to build a bobber ~

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PHOTOS/VIDEOS

Click on each image to enlarge or view as a slide show

The Project Bike -- 1984 Kawasaki ZN1100 LTD

My current ride - 2007 Victory Vegas

My former ride -- 2002 Victory V92C

Another shot of my old Vic V92C

My old Kawasaki Vulcan 1500

Stripped-down project bike

Stripping the paint off the tank, in progress

Rust inside fuel tank

Rebuilt fuel petcock/tap

Replacement Parts for the 84 Kawasaki ZN1100 LTD

Materials for cleaning out the rusty tank

Swirling muriatic acid solution in the tank

Flash rust on underside of tank

Pieces of tank liner removed along with the rust

Tank -- Before (inset) and after removing paint and decals

My sandblasting rig

The Barrel Blaster Sandblasting Cabinet

Mollie the shop dog

Love at first sight

Mollie at 10 weeks

Evercoat Rage body filler for tank repairs

Tank with primer and filler

Painted tank, ready for buffing

Materials used to get small particles out of tank

Rolled cotton in filler hole

Rolled cotton in sending unit hole

Small particles inside tank captured in rolled cotton

Sending unit

Sending unit assembled in tank

Fuel tap

Fuel tap assembled in tank

Filler cap

Filler cap assembed in tank

Finished tank

Original side covers on project bike

Side covers prepared for using Plastic Bonder

J-B Weld Plastic Bonder

Fiberglass cloth and plastic bonder on back of cracked side cover

Painted side covers

Finished side cover

Shims for adjusting valve clearances

MotionPro valve shim tool

A broken cam cap set me back a few days

New valve cover gasket

Making sure the mating surface is clean

Cleaned up carbs

Cleaned up carbs

Cleaned up carbs

Project bike on crane = a real back saver!

Clutch cover (left) after a good sandblasting

The ZN exhaust, looking rough and in need of an overhaul

chopped-up exhaust

When in doubt, organize the garage

Tail pipe expander

Dent on header pipe #4

Small dent on header pipe #1

My first attempt at welding

My first attempt at welding

Bolt tack-welded into exhaust pipe to close up hole

Small hole repaired on tail pipe

Almost 50 years after I chopped my first bicycle, I'm building my first bobber from a 1984 ZN Kawasaki LTD, in my garage, using basic tools. Follow along.

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And away we…
Paint
Brake lines and carburetors
Controls and other stuff
It’s starting to come together
Back to work

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