Kiwizook's resto

[kiwizook]

So, I recieved my su carb, but got some issues with it, see this thread about it:

http://forum.suzukiclubuk.co.uk/vi ... /start,10/

i decided to take of the front clip to make it easier to work on my rig. took me about an hour by myself, took the doors of too, and had to grind 4 philips head bolts. here is how she looks now

front clip removed

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I put the doors back on, just to keep the water out for now.
this is what the wheel arches look like, so they might need some fixing up!

wheelarch

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and I bent the warm air hose holder thingy on top of the engine, to make a bonnet support

bonnet support

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so there's some progress, albeit slow, it's there

[dan_2k_uk]

Bit strange how and where those arches have rotted. suppose in different environments and driving in different conditions they will rot in different places. (guess it has been driven on a lot of gravel/stones and it has chipped the underseal and paint off the arches directly above the tyres and rotted there.

[kiwizook]

So, I had to modify the float chamber on my new su carb, as it was sitting on an angle, because it used to be on a sloped manifold. So I went from this,

old float chamber angle

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To this...

new float chamber angle

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I just chipped away at the colar with a wood chisel, untill I got this,

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the male end of this is this,

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I hope you understand what I did. I though it worked out quite well.

I also started to make an adapter plate for this carb

start of adapter plate

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I just got to make the holes for the new carb in this plate,, and bolt it on with the throttle cable bracket I still have to make. this will hopefully run sweet.

And i found this, obviously someone has been opening the door way too hard, for a very long time

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[ScottieJ]

Coming on nicely! I started cutting all the rust out of my LWB over the weekend, it's not quite as bad as yours though, looks like you've had to cut a lot out of the bulkhead

That looks like it should work well with the carb

shame about the door shuts though, Ive not seen that happen before, I wonder if a previous owner didn't have the little metal protector bit on the strap fitted at some point?

[dazerede]

Good job on the Su carb let us know how the carb gets on might get one in the future

Can't wait to see it finished

[kiwizook]

That's not even everything cut out of the bulkhead either. I still have to cut out around the accelerator pedal support, but I left this for now, so I can test my carb, and drive it over the backroads to the place i will be welding on it

Will keep you lot updated on the carb too, hopefully it'll run sweet

[kiwizook]

so I finished the carb adapter today, and put the carb on the engine. no pics of the carb on the engine yet, but here's some pics of the adapter I made

adapter plate front side

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adapter plate back side

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adapter on carb

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I connected the fuel line, the vac advance, and managed to stretch the choke around, to just be able to operate temporarily. I fired it up, and accalerated by hand, and it started up and ran with not many problems . I kept the choke on, and the accaleration had to be done slowly, or it dies on me .

I tried restarting it, but it wouldn't after i stalled the engine. The battery was going flat too, so I'll give it a jumpstart another day.

the accaleration cable was too short to reach this carb , so I started to make my own using pushbike brake cable. works quite well, just have to fit it off tomorow, and repeat for a choke cable. Hope I can get it to run fine

[dazerede]

Looks good mate if I was u round of the edges on the adapter

I had a new battery on my zook when I picked it up and it only lasted 5 months because I swapped engines and had to wire up lights

[kiwizook]

So i took my front clip to the workshop at work today and did some welding.
I tried to put some 0.6 mm wire in the welder, but it didn't really work. first the spool of wire wouldn't fit, and when I got that sorted out, She kept jaming up the wire, and folding and looping it. Not Good

So I put the 0.9mm wire back in, and welded a bit, only to find out the gas ran out again

I just got sick of it, and stopped it. Here's the welding i did

outside

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outside 2

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inside

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so I had to grind it back a lot, and it looks okay, I just hope it will hold together. I will also build the groove up properly with some body filler later on. I might get my own welder, and put some thin wire in it, and see how it goes

[dan_2k_uk]

Always fustrating when things dont go your way.

Have another go with some new gas another day.

Dan