FZR600 Yamaha Blaster

rshutchinson

XS400 Addict
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I've been showing progress on this over on a Blaster specific forum but thought I'd share here what I've been working on since finishing the XS.

I'll just share some pictures to get it to where it is now.

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Lengthening frame

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I then picked up another blaster with extended swinger, a-arm extensions and all hydro brakes that I swapped to mine and resold it. Those parts are on in the following pics.

Engine in.

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New top tubes bent and tacked in. Also slugged these tubes to the existing frame.

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Beginning of the new exhaust. I didn't want to lose any ground clearance since I am riding trails with this so I sent the exhaust out the side above the frame rails.

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Had to add flanges so I can remove the exhaust as they had to bend around the frame.

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Banged out a metal gas tank to fit between the seat and engine

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Electronics tray

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Have to remove the engine from the side so I made all the left side engine mounts bolt-in.

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Retro'd a projector I had laying around into the stock housing

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Lost 2 leds in the halo when I pinched the strip gluing the projector in
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That's most of the fab work. Have a few things left to make. I skipped over some small stuff here and there.


Now on to making it look good. Going with black/white frame with blue pearl and majestic blue.

Majestic blue swinger. Looks almost black in the dark. Very deep blue in the light. I like it.

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Polished the steel axle, hubs and sprocket in the blue, carrier in white with blue pearl. It's difficult to get the pearl to show in pictures but it really stands out in person.

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And that's where I am at for now.
 
Looks neat. Unfortunately I know nothing about quads. Hopefully one day I'll change that.

This is my first ATV I've ever owned. I've rode my brothers small 250 a few times but and some friends but never had my own. This should be fun.

looks great, I hope the frame can take the extra power

I hope so too, haha. I have added extra bracing and gusseted the whole frame though so I think it should be fine.
 
Coated the calipers in gun-metal with a little blue flake. Hard to see, should have had more in it.

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Powdered the rest of the blue parts.

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Took everything off down to the frame so I can blast and put some color on it.

I ordered a throttle, cable and grip set off ebay. Only got the throttle housing and left grip in the bag.... somehow they didn't send the cable or twist grip... So now I'm back to waiting another month for them to send that off.
 
Blasted, primed and base coat done on the frame. I'll have to pick up some more clear this week as I don't think I've got enough and I'll have some pearl laid down on it.

Not sure I like how the 'blending' came out but it's good enough.

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So I re-based the frame since itd been too long by the time I got the clear. I like the blending more this time around.

I really went all in with the Pearl in the clear, so much so that it tinted the black of the frame to a blue. Happy accident as it is an exact match nearly to the majestic blue powder I used.

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It's much more pronounced in person but I kind of got the blue pearl in picture.
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Finished up the bumper. Added the corner pieces to protect the rad from rocks, logs etc.

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Finished up my wiring today and filled with oil and coolant and got it running. Now to just make a tie-down for the battery and fill brakes with fluid while I wait for my throttle and cable to come in. I need to order a parking brake block off to finish the rear brakes. The gauges I'll mold in to the tank cover if I can when I get to the plastics.

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Thanks Drewpy.

My battery I bought a while back I was going to use for this is no good so I'll order another. Engine isn't charging so I tested it out and seems to be the old and known to fail regulator is bad so I ordered an upgraded one of those as well. Figured I'd better not take the chance on an old one incase it blows the TCI which is expensive.

So in the meantime I finished up all the wiring and am working on the tank cover and gauges.

Cut the speedo and indicators off the cluster
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And what I'm left with
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Heat gun to the old tank cover I cut in half and started bending it. Taking shape nicely, little fiberglass work needed to go around the filters. Still thinking on how to mount my gauge in there so we'll see where that goes.


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Hot tomales mate, this thing looks bloody insane! I'm especially impressed with your painting. Is that a skill you picked up to support the hobby or did you do painting professionally? And jeeze louise, those colours are spectacular. So much depth.

I appreciate you sharing the process. It's threads that move like this one that remind me I don't need to break out the micrometer on every part I'm making. I spent 2 hours machining a stack of 11G steel only to realize that yes my edges were all parallel and shiny but no that didn't even matter because I'd overmeasured everything :shrug:
 
The painting is just something I've picked up myself, I've never had any training or worked in a shop before. I just got a HVLP gun and started doing my own stuff.

I've got quite a good chunk of the tank cover fiberglassed and sanded. It's back in one piece and nearly smooth. Then I can mould the gauges in somehow.

At least you over-measured and not under :)
 
What are your thoughts on going with plasti-dip on the plastics in black and white? Regular paint will crack from the flexing plastic and get chipped pretty easily from regular riding. I'm thinking the plasti-dip will hold up better and touch up easy.
 
Not finished yet but I'll post it up anyway with where I'm at. Don't really like how the filter glassing came out but nothing I can do about it, just how it has to be.

The gauge is just sitting in the hole for now, it'll sit up a little bit higher to clear the linkages.

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