Ok, let’s put a rear hoop on this KZ 750 twin. Charles came to me needing a little work. He wanted a rear hoop and tail light installed on his bike. So I said, no problem! Charles was also wanting the tail light to be set into the frame.
I first started out concentrating on the rear hoop. Measuring the distance between the frame rails I knew it was going to be wider than my dies diameter. I have run into this in the past and found that making smaller bends and bringing them together to make the right size hoop is the answer. The side effect is more of a pitched shape to the hoop rather than the conventional U shape, which I dig. I attached the hoop with solid slugs that are plug welded as well as welded at the seam.
Now on to the tail light “pocket”. This is all sheet metal work and I’m using 20ga steel. I made what I call the “backing plate” first. I trace an elongated oval and cut it out. Then I radius my piece to the same curve of the new hoop. For the “pocket” I bend 20ga around a piece of .5” OD round stock, making sure it’s a 180 degree bend. Then using the “backing plate” I trace out the excess material to be removed. After it’s removed the backing plate will take its place. At this point the tail light pocket is made and needs a place to go. I cut out a section of the new hoop to make room for the pocket.
Once I weld the pocket in it’s just a matter of cutting the protruding material to leave a clean profile in all directions. The light will be contoured to the hoop and set in the pocket. Now, Charles has a sweet custom hoop and more over his tail light is set in the frame!! I dig it and so did Charles!!
OK, an Albuquerque local got ahold of me and asked if I could do some work on his ’81 Kz440. I said “hell yeah”!! Aaron had a list of things he wanted to do. I would say this is the first step. Here I was to shorten the subframe, shorten the rear fender, add a rear hoop, and make a custom seat pan.
I stopped the frame about mid-way over the rear tire, made a hoop, and burned it in with a slight angle. Next I was on to the fender. Reusing one of the original fender mounts I cut off the subframe, I moved it further in toward the motor and burned it in. This allowed me to use the entire rear fender while making it appear shorter. Once the hoop and fender were done all that was left was the seat pan. I always make my seat pans by tacking and building right off the subframe. This allows for a clean tight fitment. Once I have the skeleton built I cut it free and skin it with 20ga steel.
So far the Kz440 is coming along nicely! Lets see what we can get into next!! Stay tuned…