My ZX12R evolution (or "What's going on in the Fatcave today?") - ZX Forums
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post #1 of 380 (permalink) Old 03-15-2013, 06:38 AM Thread Starter
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My ZX12R evolution (or "What's going on in the Fatcave today?")

I'm the original owner of a 2000 ZX12R that I bought in April 2000. I saw pictures of the bike in the fall of 1999 and fell in love with them and then when I saw them in person in Gainesville,Florida at the spring Prostar race and then again a couple days later at Bikeweek in Daytona I decided I had to have one. When I got home from bike week I immediately put my 98 ZX9Rand my 87 GSXR 750 up for sale.









They both sold to the first person that looked at each one. I took the money and went & bought one of the first green ZX12R's that arrived in Southwest Ohio. The owner of the dealership is also an old friend so he gave me the list of bikes coming in and let me pick the VIN number I wanted. I rode it and raced it in various forms over the years.
That's me giving it the business:

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #2 of 380 (permalink) Old 03-15-2013, 06:45 AM Thread Starter
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I added different stuff to the bike over the years and a few years ago I started a turbo build. Now I'm finishing that build and I will be riding the beast this summer.









If the header looks familiar to some of you it's because it started life as a stock ZX12R exhaust.
This isn't an off-the-shelf-kit. I designed it in my head and my brother and I fabricated it.He's certified in every form of welding there is except for underwater (we have a cousin that does that). I'm an aircraft mechanic by trade (24+ years and counting) and my specialties are structures and sheetmetal fabrication. I'm going to try my best to keep this updated as things progress, so stay tuned.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html

Last edited by 2fat2fly; 03-15-2013 at 06:48 AM.
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post #3 of 380 (permalink) Old 03-15-2013, 06:49 AM Thread Starter
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Yesterday's project was installing an oil pan window (windage tray) in my ZX12R.







And installed heat wrapped exhaust.


"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #4 of 380 (permalink) Old 03-15-2013, 06:52 AM Thread Starter
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It will see the dragstrip, but it has to completely and fully be able to perform on the street as well. All signals, lights, horn,etc must work as advertised. Basically I want a clean looking sleeper.

All the additional toys will be hidden inside the bodywork so the average Joe will not notice anything when looking at it. To the trained eye or anyone who knows ZX12's it will be obvious that things were done to it but it won't necessarily be obvious as to exactly what was done.







Oil cooler was relocated:



"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #5 of 380 (permalink) Old 03-15-2013, 07:58 AM Thread Starter
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The ZX12R's always had a very "iffy" fuel pump. They weren't designed to handle much horsepower over stock so I upgraded to a Walbro pump. It's not really impressive to look at. If you didn't know better you'd think it was still a stock unit except for the bigger pre-filter (sock).



While I'm addressing weak links, the clutch is a timebomb in a 12. The stock basket will explode eventually on the dragstrip or even if abused on the street. That's why I went with Muzzys clutch kit:



and a billet clutch basket from Falicon:




"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html

Last edited by 2fat2fly; 03-15-2013 at 08:09 AM.
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post #6 of 380 (permalink) Old 03-15-2013, 08:24 AM Thread Starter
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Several years ago I stretched the swingarm 4 inches and this forced me to remove the stock undertail. I made a new one out of aluminum but it was flat and the rear tire would hit it on a hard launch. I modded it with a recess in it to enable hard launches without hitting it anymore:





In the pictures you can see where the tire used to hit. I will paint it with the rest of the brackets I still need to fabricate. I need to brace the pan the oil cooler sits on and make a bracket for the scavenge pump to mount. I also have to mount the new fuel pressure regulator as well. That will be a nightmare I'm not looking forward to.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html

Last edited by 2fat2fly; 03-15-2013 at 08:35 AM.
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post #7 of 380 (permalink) Old 03-15-2013, 11:34 AM
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All of your bikes are amazing! This one is no exception. Can't wait to follow your progress and see the finished project. Saying that it will be a sleeper is an understatement. Keep us posted.
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post #8 of 380 (permalink) Old 03-15-2013, 11:49 AM Thread Starter
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Originally Posted by ninjanut View Post

All of your bikes are amazing! This one is no exception. Can't wait to follow your progress and see the finished project..

Thanks. That means alot.

Quote:
Originally Posted by ninjanut View Post
Saying that it will be a sleeper is an understatement. Keep us posted.
That's the plan. Hopefully it works out that way.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #9 of 380 (permalink) Old 03-15-2013, 11:59 AM Thread Starter
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I spent today figuring out the fuel delivery and return system.
I'm using a Walbro pump to feed this thing and although I'm cheaping out right now and using the waste gate and blow off valve springs to control the boost, it won't stay that way. So I need to be able to feed the horses when they want hay. That's why I'm using an Aeromotive fuel pressure regulator to maintain fuel pressure. These things use AN fittings to connect it to the fuel system and the ZX12R uses 5/16" rubber fuel line so I needed to connect the two. I went to Jegs (they're right down the street from where I work) and bought braided line and fittings to make the connections. I also went to NAPA and got some high pressure rubber fuel line for that side of it. I'm locating the FPR on top of the valve cover due to space restrictions everywhere on this bike and running the lines to connect everything from there.









It looks sloppy right now simply because nothing is completely tied up. Trust me, when it's done everything will be secure and you won't see anything I don't want seen. As you all can see I still need to make the mounting bracket for the FPR. It's on my list and I plan to have it done and mounted by the end of next weekend.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #10 of 380 (permalink) Old 03-15-2013, 12:07 PM Thread Starter
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This beast still has the dry nitrous system installed. I'm keeping it in there for now.









It's also sporting Muzzy velocity stacks. I don't need them for boost containment at the moment but I might down the road....

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #11 of 380 (permalink) Old 03-15-2013, 12:12 PM Thread Starter
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Here's a better look at the pan the oil cooler sits on:



The oiler cooler itself is originally a power steering cooler from a 1999 Ford Super Duty pickup. I cut the hose ends off and my brother welded AN fittings on. We also reversed the angle and orientation of the cooler so it sits lower and is angled for max airflow across it from the now unused ramair snorkel.



As you can see the cooler needs some trim work done. That's another project for this week.

The other part of the oilcooler relocation is the Muzzy oil filter relocation kit:









It provides the mount for the oil filter and the block off for the original oil cooler. You supply the filter,cooler and all oil lines. The good part of this kit is the extra feed line that I used for the turbo oil feed. You just need to run an in-line restrictor to keep oil volume down. Otherwise you can blow the seals in the turbo. That will make for a bad day.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html

Last edited by 2fat2fly; 03-15-2013 at 01:49 PM.
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post #12 of 380 (permalink) Old 03-15-2013, 02:00 PM
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Really nice!
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post #13 of 380 (permalink) Old 03-16-2013, 10:21 AM Thread Starter
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Originally Posted by steell View Post
Really nice!
Thanks!

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #14 of 380 (permalink) Old 03-16-2013, 10:24 AM Thread Starter
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Today's plan is to mount the scavenge pump and lay out all the brackets I need to make. Tomorrow I'll go to work a little early and make the brackets. I'll be able to prep and paint them on my breaks so they'll be ready to take home at the end of the day. It's not exciting and there will be very little visual progress but it's still forward progress.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #15 of 380 (permalink) Old 03-16-2013, 11:00 AM
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This. thing's gonna be a monster, 2fat. If I ride to Pennsylvania early this fall, I might have to drop by and check it out.

It may be a pig, but it's a pig with a rocket in it's ass!
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post #16 of 380 (permalink) Old 03-16-2013, 11:18 AM Thread Starter
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This. thing's gonna be a monster, 2fat. If I ride to Pennsylvania early this fall, I might have to drop by and check it out.
You're always welcome at my house.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #17 of 380 (permalink) Old 03-16-2013, 11:23 AM
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Re: My ZX12R evolution (or "What's going on in the Fatcave today?")

Very cool project. And nice fabrication skills (kinda like what I always suspected an airplane mechanic would have)

Sir Flower Child, Welcome Wagon Howdy Whore of ZXF


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So EZ, a caveman can do it.
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post #18 of 380 (permalink) Old 03-16-2013, 11:36 AM Thread Starter
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Originally Posted by rileydeed View Post
Very cool project. And nice fabrication skills (kinda like what I always suspected an airplane mechanic would have)
Thanks Riley.

"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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post #19 of 380 (permalink) Old 03-16-2013, 12:05 PM Thread Starter
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Scavenge pump is physically installed but not wired in yet.I'm waiting to do all the wiring in on shot. I still have some electronic goodies to install and 3 gauges, so I'll wire it all at once. Here's the pictures of it:





I will slide the rubber scavenge pump hose in a heat sleeve next weekend. I got the wrong size on my previous trip to Jeg's so I have to wait until later this week to get the right size.

While laying out the brackets I need to fab I put some of the bodywork on the bike to make sure everything will disappear once it's all together. Here's some shots of that:






"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html

Last edited by 2fat2fly; 03-16-2013 at 12:40 PM.
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post #20 of 380 (permalink) Old 03-16-2013, 12:29 PM Thread Starter
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When I address the wiring I'm going to add a toggle switch to the left side of the triple clamps. There are already 2 on the right side. One is for arming the nitrous and the other is for arming the air shifter. The airshifter, when armed, uses the horn button as the shifter. The nitrous, when armed, uses the starter button as the nitrous button. You can see the toggles in the next photo. The red button on the left, just inboard of the left controls, is for the air compressor to fill the air tank. The swing arm is pressurized and used as the air tank.The bracket that has "MPS" on it is the kill switch for drag racing. The last photo shows the air pressure gauge for the shifter and the Autometer shift light.








"Any man who thinks he can be happy and prosperous by letting the government take care of him --- better take a closer look at the American Indian." Henry Ford

My Turbo ZX12R Build:
http://www.zxforums.com/forums/zx-12...ave-today.html

My 1993 ZX7R (M1)
http://www.zxforums.com/forums/zx-7r...r-real-m1.html

http://www.zxforums.com/forums/zx-7r...-m1-naked.html
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