Endo's Project Darkside: ZX6E

Checking back in!

2011-11-10T17:49:00.002-07:00

Wow, it's been almost FOUR YEARS since the last update on this.

I've had a few people dig up the build and ask me to update the pictures as several links were broken, so here you go! All done...

Also, I never posted back up that the bike did win an award for Most Complete Theme in the CustomFighters.com 2007 Buildoff. I did sell the bike to a local fella and have heard many rumours about it's current state from write off to blown engine so who knows where it actually is. I know it got spray bombed gun metal grey shortly after I sold it but it's his bike now, he can do what he wants!

The bike was also featured in a British online magazine called Sub-Zero Magazine. Scans of the article will be placed at the end of this post in a few days, along with pictures from the photoshoot.

This blog will be migrated soon to my new site, www.redefyned.com where you'll also be able to follow my current build which has been ongoing since 2008...it's a 1989 Suzuki GSXR 7/11 with nitrous. This build has taken a long time but the end result will be worth it for me, it's a no compromises build I've been planning for years!
Current progress can be seen here:
http://customfighters.com/forums/showthread.php?t=12491

Thanks for checking in and thanks again to Jeff (Sevulturus) for his hard work in chronicling Project Monster!

Chapter Closed

2008-04-18T21:33:00.003-06:00

The day has come and gone---

Project Darkside, now known simply as Monster, has gone to its new home. It is in good hands I trust, with a great and excited new owner. My GSXR was also sold a few months ago...

Thanks to everyone who has visited this corner of the interweb to follow this, and keep an eye out on Customfighters.com for my next build---a nitrous injected, big bore GSXR 7/11.

FOR SALE - Project Darkside/Monster and my GSXR

2007-09-23T18:37:00.003-06:00

The time has come to part with Project Darkside/Monster. While I'm sure I'll regret it, there are future projects that require my attention and finances. I'm sure through reading this website, you will understand what has gone into this bike, and appreciate it as so many have. This will NOT be my last build, I'm just not rich :D

Please scroll down to see pictures and specifications.

2007-05-31T21:31:00.000-06:00

Well, that's all for this build...for now.

I am very proud to see what I started with and where it's come, especially for my first ever build. I hope you all like it, and thanks to all those who followed this build.

There was a lot of work done, not all cosmetic either The bike was completely stripped, all bearings and seals replaced, wiring redone (including stator outputs), and a lot of other "get it running" type stuff. When I bought the bike it didn't run proper (was dropping a cylinder), and the chain was misaligned by an inch (among other things). Now she's all straight, running great, all tuned up and ready to go. It still needs some jetting, but it's rideable! I'd estimate I have well over 250 hours into the bike and probably 90% of that was maintenance and rebuilding. The other 10% being cosmetic.

Here's the Spec list!
Acerbis Flyscreen
Acewell Gauges
Drag Style Handlebars
Barend Mirrors
Harri's ZX Racing Grips
Harley Davidson 883 Sportster Fork Mount Signals
Yamaha Virago Handlebar Clamps
Handlebar Risers (old valve springs)
Single Stage Gloss Black Paint
Frame painted Gloss Black
1999 Yamaha R6 Subframe/Plastics/Seats/Taillight
R6 subframe modified extensively
Custom Monster Energy Coolant Overflow bottle
Sprockets used for frame/subframe gussets
Chopped Bandit Exhaust Canister
Vortex Sprockets/RK Chain Set (stock/+5)

One-off owner/friend built parts include:
Exhaust Hanger
Exhaust Can
Subframe/Frame Gussets
Stainless Undertail
Subframe Mounts/Lifters
Bellypan Joints
Battery Box

All Mechanical Work Done by Owner and Friends
- Steering Stem Bearings
- Fork Seals
- Wheel Bearings and Seals (front and rear)
- Carbs cleaned. rebuilt, and sync'd
- Valve adjustment and timing adjustment (don't get me started)
- Swingarm Bearings and Seals
- Stator Output Wiring (thanks Brad!)
- All other wiring and electrical

Now, because it's a long post already, here's my Thank You's.

Melinda, you rock baby, thanks for putting up with me! And thanks for cutting the "endo" decals on the tank.

To all the friends that have pitched in to get this done be it with screwdrivers, cameras, words, or inspiration.
- Joe Dunderdale (BritJoe) - the brackets, the support, the garage space and tools, the guidance, the inspiration and the friendship. This bike would not have been completed without your help.
- Brad Chorney and Dan Bruce - My instructors at school. Fountains of Knowledge and two of the most ingenious people I have ever met. Thanks for the knowledge, guidance, the input and for staying late more than once in shop so I could continue to work. Thanks for everything you've provided, including the career. It was a pleasure being your student.
- Jeff Dewald (Sev) - the moral support, the mechanical help at school, the blog entries and their excellence, the input, and the friendship.
- D McCormick - more moral support, a great friendship, so cool ideas, the extra set of hands and the cool Exile Cycle hat!
- Ernest Barbaric - the addiction...what more can I say? You got me hooked on this concept!
- Lanny Irwin - The plastic welding, great job man, the bellypan looks like new!
- Brad Ewing the Welding Instructor - ummm....the baking? No, the finish welding you did for free, on a tight timeline to make everything come together.
- Derek Pauletto at Trillion Industries - The inspiration and passion for custom work, the fabrication, the input.
- The crew at Universal Cycle - getting me the parts on time and the extra set of hands that was always available, you guys rock.
- Ryan Jarmaine - the paint and bodywork...someone else fell through on their commitments, but whether you hated the job or not, you did fantastic work for what you had to work with (a 4x6 room in a dirty quonset), and you did it on a tight damn deadline. Thanks for everything man!
- Ian and Amanda Tong of Signetix - the local team who did awesome in a short time frame to hook me up with the Monster Energy themed graphics.

I know I'm missing a bunch, I'll add them as I remember. If I've forgotten you directly, email me and I will give you your dues!

Lastly, the online resources that have been priceless in this build
www.zx6e.net The single BEST resource, online or otherwise for ZX6 owners.
www.groundpilots.com
and of course, the guys who started the buildoff, www.customfighters.com

It has been tedious, pleasurable, hard, and fun to do this...keep an eye out for the next one!

THANKS!
Josh

PS I am not in any affiliated or sponsored by Monster Energy, I just love drinking Monster Green!

Codename: Darkside

2007-05-27T09:18:00.012-06:00

As so often happens in the entertainment industry a project is undertaken using a codename or psuedonym. Project Darkside was a similar exercise in secrecy. From day one inspiration has flown from one source. That little black and green can that contains the sweet nectar of the gods. Many late night building escapades were fueled merely by high hopes and enough energy drink to induce heart arrhythmia.

So without further ado I introduce to you the true face of Project Darkside: Project Monster.

So, required image for judging front right view. Take note of the monster type slash across the front fender. Not to mention endo's proud branding on the tank. Don't forget the custom fabbed exhaust hanger :D!

Required image number two. Rear Right. I'd like to draw attention to - the subframe mounting brackets made of an old chain sprocket and the custom fabbed coolant reservoir - anodized with a monster logo. You can also make out the Acewell gauge carefully tucked in behind the windscreen. The undertail was handfabbed by endo, and the exhaust is a cutdown version off a GSXR if memory serves (I'm sure I'll be corrected here later). Barend mirrors and custom green grips tie the front to the back.

Required image number 3 Rear Left. Again, you can see the custom coolant reservoir. The hugger itself was painful to track down, originally a sick off-teal color it's been repainted and the classic monster brand added.

Racing stripes pulled directly from the monster can pull the entire bike together - they carry through the seat into the tail. And we're gonna rep custom fighters to the nines.

Finally the Front Left. I don't think anything else needs to be said about the bike at this point. Just enjoy the view.

Now for the glory/random shots.

I think this is one of my favorite pics because you can see how well the bike ties itself together. The front and back wheels mirror each other with the use of similar looking plastics. The hugger and fender look the same. The black bellypan balances out the black of the tank and tail above the engine giving the bike as a whole a more complete look. And the angle of the tail ties in very nicely with the angle of the tank. Not to mention the clean way the Acewell headlight and Harley indicators finish off the front end.

Moooooonster!

At this point, I would like to offer thanks to endo for including me in this build, it's been a pleasure to work alongside you. And congratulations to him. As even if he didn't win the buildoff, he's still built something to be proud of. A winner in his own right.

The astute amongst our reader base will have noticed small hints as to the final direction of this build. Small comments about monsters, or the color schematic on the page. Little things, but we had fun doing it.

Born Too Slow

2007-05-26T19:00:00.000-06:00

What are you doing right now? Me... I just got out of the shower after a hard day at work. endo on the other hand is sequestered away in his garage wrenching like mad. Loud clangs and louder saws can be heard. And a knock at the door is greeted with the suggestion that the intruder "wander away and proceed to transition to a different state of entropy."

I'm looking forwards to seeing the final result.

Dreaming in Neon Black

2007-05-21T17:08:00.000-06:00

So at this point in time I'm faced with what some might call a rather difficult predicament. I live in Edmonton, Endo in Calgary. That's about 3 hours between us. We're also working hours that should be considered sickening.

Despite all this he continues to make progress on Project: Darkside without my interfeara... I mean help. Which leaves me in the unenviable position of updating a blog that I have no direct access too. Now, I could make up a bunch of wild stories of daring do and exciting adventure. Or I could just let Endo do all the work... but I've already received payment for the words that flow forth from these golden fingers so let us away.

Today Endo and I met halfway between here and there (I believe it's called nohere) and he filled me in a little. Which is to say he gave me some pics and told me generally what was going on:

Darkside is running, infact she'll bring the front end up in the first three gears without trying. Though you can smell that the mixture is... a little rich. Going to take a little tuning, and she's loud as fuck. Which is not necessarily a bad thing. We continue to keep our eyes open for an orignial Z1000 exhaust. You would think that with me working at a Kawi dealership there would be lots floating around... but that is sadly not the case.

Last week Darkside went in for paint.

After careful masking a subtle coat of gloss black was layed down. I know it's tough to see, but if you look close enough you'll notice it.

The subframe received a similar treatment.

And because I'm a prick, here Haelo is why the buildoff final pics should include a sideshot.

AND, the Acewell gauge is all wired up.

The plastics are in the shop for custom paint, and we're hoping to see everything together by next weekend.

Enjoy the rest of the buildoff :D!

Moving On Out

2007-03-23T21:49:00.000-06:00

Not ten minute after we finished getting the bike together endo was rolling it into his truck and headed out of Fairview.

Wiring, Brackets, and Sprockets That Fit

2007-03-22T22:51:00.000-06:00

So, like we said in the previous post the subframe no longer lines up with the mount holes on the frame. We needed to find a way to move a hole about 1 inch. So "D" and I piled into the machine shop to look through the scrap metal.

Meanwhile endo took the time to lay out his wiring harness. And cement it in place, as you can see he's using a highly technical method to secure parts in place. Electrical tape.

endo slapped the tail plastics and seat into place and took a couple of shots.

Meanwhile "D" and I were floating about the machine shop, and found two things:
1) A piece of flat steel to make brackets out of.
2) And "D" found a rear sprocket off an old CG125 - and he started thinking.

Bring the metal back into the shop and endo starts to mock stuff up. He makes a nice heart shape on the metal and gets ready to start cutting.

Three sawblades later he's got the shapes cut out and starts filing down the sharp edges. Drill two holes and it's time to finally put the subframe into place. Talk about a momentous occasion, this moment has literally been 9 months in coming.

endo took the first and only test sit. And as you can see it looks good. Finally got the tail to line up correctly with the tank, and the angles are starting to come together. It is going to be a sweet ride.

While endo was making sure his subframe would remain attached to the bike by more then a wiring harness and good intentions "D" and I were playing with the sprocket that he found (on a bike). "D" is the one with the sweet tattoos.

We went with the subframe gusset rather then the spikes off the windscreen :P Looks cooler.

Sadly at this point pieces for "D"s engine came in and he had to get back to 'real work'. That left me by myself to see out his vision - I'm a fabricator and now I'm stuck not only creating something from nothing, I've also got to take pictures. Sorry if this section doesn't make much sense.

After taking off the sharp edges and sandblasting they get handed off to endo for paint.

Everything is painted, so it's time to put it all together.

On Ends and Angles

2007-03-21T01:08:00.000-06:00

Who here took trig? Who here remembers basic measurement? Endo and I did both and we managed to forget everything we learned. Take that math 30 teachers! HAHAHAHAHAHAH!

Sigh, how is it that the best laid plans of mice and men always seem to go awry?

This is what the bike looks like as we start to work on the subframe. The goal is to move the whole thing forwards so that the large gap between the seat and the tank is closed up as much as possible. Out come the Vernier's along with about 30 sets of hands and consultants galore to figure out what to do.

A course of action is rapidly decided upon and damn the consequences.

It's time to start ripping and tearing:

Okay, so we've got the subframe off it's time to start mocking things up:

A solo seat was discussed, but finally discarded as an option for a couple of reasons. It's tough to do right, it's very tough to get a clean looking tail, and this HAS to be a two seater.

We stole the tail off a classmates Ducati (we had to beat him up first) but gave it back after test fitting and not liking the result.

The only option left was to start cutting on the subframe. Lay everything out first then haul out the hacksaw. Dress the cuts with a file afterwards and hand everything off to the welder... cross your fingers that it comes out the way you want. In the first picture you will note that the mounts are being locked in place a 10mm threaded dowel and some nuts. This keeps the correct spacing for the mounts and helps the welder get everything positioned exactly where we need it to be. How handy is that?

Okay, so here's the problem. When you cut down two sides on a triangular shape say... this "V" what happens? Well the distance between the two mount points (the flat spots at the top of the "V") is reduced "v". Taking that two inches off the subframe meant the mounting holes didn't line up with the frame anymore.

DAMN YOU TRIG!

Guess it's back to the machine shop to get a mount bracket going.

Springer Front End

2007-03-10T18:05:00.000-07:00

Here's a first for a streetfighter. A springer front end. Well, our take on a springer, and I can promise it's like nothing you've ever seen.

Endo has been having trouble deciding what he wants to do with his handlebar risers. They protrude from the front end by about 2 inches, and just plain old look bad. Because endo was waiting for engine parts for his safety council bike (the bike he needs to rebuild to pass the course) he decided to pass a little time working on the fighter.

No one was happy with them. It was decided that a spacer was required, so endo got out his vernier's and went to work.

Four hours worth of measuring later we were no closer to getting anything done then when we started. So we went hunting for something to machine into a spacer. While poking about in the machine shop endo and Brad (instructor Brad) found quite a few old chunks of aluminum that could have been run through the lathe. But nothing that seemed quite right.

While digging through boxes of old stuff this one turned up. I think you can all tell what's in there.

And you can all see where this is going... the box was tossed aside, then in a moment of what can only be described as mutual inspiration endo and Brad turned to each other and just smiled.

Seconds later valve springs were being inserted under the handlebar risers and tightened into place.

What's that? More pics? Of course!

Next endo shows off his fab - fabrication skills (yes I did that on purpose). And builds a spacer for the bottom of the triple trees to spread out the force that will be put on them.

Change of Plans

2007-03-06T20:34:00.000-07:00

Okay, so after much discussion and the realization that many of the other members are going gloss black and matte black the conclusion has come that we need to stand out. In a big way... so we're taking a bold new direction lets just say that pink and sparkles feature prominently in the new design.

You Let The Smoke Out!

2007-03-02T21:43:00.000-07:00

For the last week or so endo and I have been learning about motorcycle charging system. What does this mean? Well our instructor, Brad Chorney has a single overruling principle that guides every action in class. "Electrical components - all of them - have smoke trapped inside. So long as you keep that smoke inside your stuff will work. If you let the smoke out, it won't work anymore." The whole class has subscribed to this theory and we're progressing rapidly.

On the Thursday before spring break we decided to test Project: Darkside to make sure that everything was peachy keen. Battery voltage, amperage drain, and most of the wiring all checked out nice and clean. All the lights functioned, the starter started and the horn horned.

However when it came time to check the AC voltage output of the three coils we ran into something interesting.

We were both rather shocked at what we found in there, but rather then leaping to conclusions we decided to investigate a little more.

After 10 minutes of fighting with the darn connector we realized that it was fused shut... literally melted together. Okay this seems bad, but hopes remain high.

One solid tug revealed this. And we promptly did what any bike owner (or mechanic for that matter) worth his salt would do in this situation. Freak the FUCK OUT!

Fast forward five minutes and a whole bunch of words our respective mommies don't know that we know and we were able to look at the problem with a somewhat level head. Meaning I kicked endo in the knees until he was at eye level for me.

Endo decided that suicide was the only option and hauled out the razorblade but missed his wrist and cleaned up the connection a little bit he got his finger though, see the mechanic's bandaid? Five minutes of cutting allowed us to disconnect the plugs. It was UGLY in there, I've not seen that much burning/corrosion in a long time.

At about this time we enlisted the help of our instructor Brad (who is a journeyman electrician in addition to being a journeyman motorcycle mechanic) for his expert advice. A quick assessment indicated that while the connector was pooched (like I had to tell you that) and although the wires were cooked for quite a bit of their length it was not overly bad.
In a matter of minutes the old connector was gone and a new set of waterproof ones were installed. We lacked a triple connector plug like the one that was originally installed so instead three separate connectors were put in place. Disaster averted, but we owe the original owner a friendly visit.
I guess we figured out why the battery didn't like to hold a charge. We're real mickiniks now.

In other news the charging system on my bike was perfect. Go Honda!!!

Perspectives: My Story

2007-02-10T13:38:00.012-07:00

First off, if mom ever reads this, sorry 'bout the language ;)

For those that care, here's my story.

It all starts at Frank Sisson's Silver Dollar Casino in 2003. My buddies Matt and Blaine (RIP) who I worked with, both rode bikes. Matt had a Katana 600 (now a 600RR) and Blaine had a gorgeous GSXR750. They are the guys that got me into street riding, after a many year hiatus from dirt/trail riding. When I got into street bikes a few years ago, I must admit, I didn't like the look of fighters. I didn't understand it. I have always loved fully faired bikes, in fact I still do. I owe my obsession to my friend 'e'. I bought an SRAD750 and shortly thereafter, met e. He also had an SRAD 750 and was a fountain of knowledge for me. He taught me a lot about that bike. He also sold me a lot of parts because he fightered his. He was born in that end of the world and grew up with fighters so it wasn't a new concept to him (in fact, he has a letter published in issue 2 or 3 of SSB). Anyways, I saw his bike and everyone called it ugly. I thought it was cool and original, but I loved my SRAD the way it was. Times moved on and a close friend passed away. I sold my beloved SRAD to buy Blaine's 00 GSXR750, as I had promised I would do when he was in the hospital (melanoma cancer at 26). I loved the new bike (still do), but I was hankerin' for something else. Then I got an email. Turns out that e was cleaning his room and found a pile of old issues of Streetfighters magazine. He offered them up, and I gladly received...I collect magazines it seems (over 500...sick I know). Anyways, I got to reading and fell in love with the power, personality, and engineering behind them. My tastes grew into a new love and my old love for Slingshot GSXRs was seen in a new light...I had to have one.

e's SRAD GSXR

Shortly after this time I started at my current job, where my boss collects and races vintage Jap bikes. More power...excellent. More exposure to the high performance stuff, and, being a wrecker as well, I noticed that I was going upstairs, seeing parts and thinking, "damn, that would look sick on this bike"...the ball had started in motion. The raw look, the bare minimum, the engineering...I had to have a streetfighter, and had to have one now. I saved up a little bit of cash, about $1000 and went on the hunt. I looked at all sorts of stuff but they either didn't fit the bill of what I wanted or were too much. Then some guy came by the shop with a 1994 ZX6E for sale...he had just moved to town and he needed rent money more than a bike. $900 and one lien check later, I owned it. "This bike is in good shape cosmetically, what am I doing" was my thought as I tore into her bodywork, but I couldn't stop. You all know the rest of the story.

While I may never be satisfied with the bikes I have, I know now where my niche in this industry is.

Endo Molests His Bike To Life

2007-02-09T13:08:00.000-07:00

So, after 6 months of hard work Endo gets his bike running. Everything from a broken throttle cable to timing so far out of whack that the intake valve on cylinder 4 was tapping against the piston stood in his way. But perseverance pays off, and she's running now.

Things to note:
1) Bike fires over at 1:19 seconds
2) The cranking in the background is some students testing starter relays on a gixxer600
3) God damn she sounds angry, one might even say Monstrous. I love this bike more every day.

To-Do List

2007-02-01T18:45:00.000-07:00

As of today, here's the list of things I want...nay, need to finish by the build-off finale. Must find a lot of time and money that doesn't exist right now! Wish me luck, and if you have anything that I list, LET ME KNOW PLEASE!

For Sure:
Rebuild Front Calipers (01-02 GSX-R1000, need kits)
HEL Braided Lines
Front Fender (needed, 1993-02 ZX6E please)
Different bars (would like 7/8" dirtbike style with cross bar)
New Grips
New Reservoir Cover
New Electrosport/Acewell gauge setup
Relocate thermostat housing - possibly entire radiator
New rad hoses and catch tank
Fit (fix) bellypan and trimpiece
Undertail
Rear Signals
Z1000 Exhaust (need canisters, right side only)
Replace right footpeg and mount
Fab battery box for placement under tank
Polish some bolts and/or buy a "Tastynuts" anodized kit
Fabricate/fashion some sort of crash cage/frame slider
Ceramic coat exhaust
Left Hand switchgear (mine has a broken choke lever)
Paint rims/polish lips
Paint/Polish Engine
Paint Fork Legs/Calipers, oil cooler, radiator, bodywork, frame/subframe, bracketry

Wish List:
Custom machined top triple clamp
Vortex anodized black gas cap

I have a lot of work ahead of me. Feel free to contact me with any ideas, shortcuts, etc.

Thanks for following the Project!

*Picture inserted by Sev... curtesy of machall comics avail at www.machall.com Hella funny check it out!*

Not Getting Much Done

2007-02-01T16:04:00.000-07:00

Endo wants everyone to know that he hasn't been able to get much done because he's decided to become a founderer... a foundee? Wait... what? A foundrist? Somethin... I dunno makes stuff outta molten metal.

You're on your own here endo.

He built a precision crankshaft adjustment tool: Big Ass Lead Hammer, he's calling it Mjolnir.

I don't know what to say to that... but okay. *Sev backs away slowly and avoids making any threatening gestures or sudden movements.*

Here's an action shot.

Come Out Swinging

2007-01-10T17:23:00.000-07:00

Have you ever been bored? Like truly and mind-numbingly bored. So bored that anything seems like a good idea? So bored that no matter how many paint fumes you have to huff you're going to paint your swing arm? No... yeah, we've never been that bored either.

The problem with removing a swingarm is that once you get it off you can see everything that is wrong with it. And when you have three linkages, this means there is a LOT wrong. In this case five needle bearings and one roller bearing, plus the swingarm pivot bolt and every single oil seal on the assembly. And shoving those buggering little bearings in there is no easy feat.

Endo loves the lube, even on the tiniest shafts...

... and as you can see he's experienced at fitting small things into tight places.

Unfortunately installing bearings is no easy feat, because they are an interference fit. As a result all the bearings get dumped into the freezer, while the wallpaper heat-gun comes off the shelf.

Expand one and contract the other. A bearing puller and molybdenum grease make sure that everything fits together.

Tadah.

Pop a new dust seal on top and you're good to go.

Lets install a swing arm shall we?

Not much to work with here, but things will change.

I'm sure everyone who reads this knows how to actually install a swing arm, so you're just going to see a series of pictures. For those of you that don't basically it's tab A into slot B. *Note avoid hole C... you'll get slapped.*

Here's The Finished Product

Annnnd we're done. It's amazing what a difference painting a swing arm can make to the appearance of a bike. The fact that it works well now is just a pleasant bonus.

Line in the Sand

2007-01-01T23:30:00.000-07:00

It's Jan 1st 2007 and today the street fighter contest begins.

As of today Project Darkside: ZX6E should be considered an official entry.

We'll wait for you at the finish line.

Reach For The Sky

2006-12-02T00:46:00.000-07:00

Legen.... wait for it...

Lyrics by Social Distortion
Reach For The Sky

So, Endo and BritJoe are sitting in Endo's shed one night looking at two things a '94 ZX6E, and an R6 tailpiece. I think you all see what's going to happen here.

When I was young I was invincible,
I find myself not thinking twice,
I never thought about no future,
its just the roll of the dice.

That's right, they changed the clip-ons. What did you think they were going to do?

Install both sets at the same time, make sure you like how they look.

Yeah, they look pretty good.

Okay, pull off the right.. FUCK, left one, the LEFT ONE!

Leave the right one on. Okay, just kidding, it comes off too.

Looks pretty good to me.

Clip ons are kinda worthless without controls.

But the day may come when you've got something to lose,
and just when you think you're done paying dues
And you say to yourself, dear God what Have I done?
And hope its not too late 'cause tomorrow may never come.

Okay, so that totally wasn't cool of me to pull that, so here you go, lets chop the tail off a bike... maybe...

Reach For the Sky, 'cause tomorrow may never come
Reach For the Sky, 'cause tomorrow may never come

This is what there was to work with, pretty basic if you ask me, but the ninja plastics are.... dated to say the least. So it would be nice to get rid of them. Lets line things up and see how they look.

Looks like things might work

Yup still looks like things will fit.

Okay, you know how most people say measure twice, cut once. Endo measures THREE times, just to be sure. He is that methodical and that careful about everything he does to his bikes.

Yesterday is history and tomorrow's a mystery
But baby right now, its just about you and me,
You can run you can hide, just like Bonnie and Clyde.
Reach for the sky ain't never gonna die,

So at this point Endo is having some doubts as to whether or not he REALLY wants to take the old tailpiece off. It's in good condition, and everything works. Why mess with what works?

and I thank the Lord for the love I have found
and hold you tight cause tomorrow may never come.

Britjoe attempts to alleviate the problem. "Hey look over there!"
HACKSAW!

"ACK GET OFFIT!"

"But it cuts so easy! See look at that, only took me a couple of seconds!

"I'm still not sure I want to do this."

Reach For the Sky, 'cause tomorrow may never come
Reach For the Sky, 'cause tomorrow may never come

Britjoe: "Fine, well get a couple beers and we'll think about it."

ANGLE GRINDER!!!

In the time it took Endo to grab two beers, Britjoe had the tail off.

"Well you were having trouble deciding what to do. I figure now you'll have to do something."

So if you please take this moment
Try if you can make it last
Don't think about no future and just forget about the past
and make it last.

Reach For the Sky, 'cause tomorrow may never come
Reach For the Sky, 'cause tomorrow may never come

...Dary

Humble Beginnings

2006-11-30T00:56:00.000-07:00

Okay, so lets show the nice ladies and gentlemen what we started with. It's actually a really good looking bike for the most part. There are a couple of cosmetic problems, but we took care of them.

Anyways, here's Endo's ZX6E, next to my gixxer.

OW, okay, it's Endo's Gixxer.

As you can see, despite my previous post it doesn't look too too bad, most of the "damage" as it were is hidden as it's the result of sloppy ass maintenance, not a spectacular crash. Seriously what kind of moron cuts off a perfectly good faring *shifty eyes*.

Can you guys spot the damage? Don't scroll down yet.

Okay there you go, footpeg mount snapped clean off.

Being a mechanic, I knew exactly what to do.

Okay, hold this... don't let go. Perfect, it's fixed.

I SAID, IT'S FIXED!

Current Mods:
Front, sides and lower fairing removed
Can shortened
Acerbis Headlight installed
Harley sportster fork signal lights
Custom Coolant Bottle
R6 Subframe and seat unit (with mini indicators and undertail eliminator) test fitted

Shiv's and Shank's

2006-11-28T23:02:00.000-07:00

As the project start date has been decided, Endo has chosen not to do any more "fightering" to his bike, though he will continue to work towards making it ridable as possible. In the meantime we're either being assisted by, or dodging this classmate's shivs. You decide.

Current Mods:
Front, sides and lower fairing removed
Can shortened
Acerbis Headlight installed
Harley sportster fork signal lights
Custom Coolant Bottle
R6 Subframe and seat unit (with mini indicators and undertail eliminator) test fitted

Where we Stand

2006-11-28T21:45:00.000-07:00

From the lowliest of beginnings...

Three months ago I arrived in Fairview Alberta to take a motorcycle mechanics apprenticeship course. When I arrived there was only one other student here who has his own bike. Endo arrived with a 1994 Kawasaki ZX6E which had the fairings torn off, the seat unit (fit replaced) with an R6 unit which is painted chalkboard black, every morning Endo gets a new wierd message from his classmates, and an Acerbis headlight. It was to be his, "learn on it," bike.

And man did he learn, every bearing on the bike was so seized it could more accurately be called a bushing, both axles and swing arm pivot bolt were too worn to be used safely. Every external seal was shot, and the front tire was so worn it looked like it may have been a race slick (the rear was replaced before he even arrived here!). The carbs looked like they had never been cleaned or synced. The forks had more oil on the outside then the inside

Most alarming was the liquid balance inside the front wheel, which even years later was still liquid and so slippery that your fingers would still feel slimy the next day if you made the mistake of touching it. That alone was an hour of painstaking cleaning, it wouldn't take much of that stuff to make the tire slip a bead.

In bits and pieces between class projects and in free time Endo slowly began to bring his bike into running shape. First a new front tire was sacrificed at the hands of the pneumatic tire change machine god. A second would have to be purchased ARGH! The crystalised sludge that was the original brake fluid is replaced and the metal brake pad liners are switched out for brake pads that actually have pads on them. Then the fork seals and oil are changed, followed by rebuilding the steering head. What a long and painful process it was to drive those lower bearings off the steering stem without causing damage to the stem. My offer to, "just lop the steering stem off above the bearing race then pound the race off," was not met with amusement. "But I've got my hacksaw here and everythin... aww... just a little?? No... awww... c'mon. Okay Okay put down the sledgehammer, I'll leave."

Sacrifice a tire, appease a pneumatic god

After that the swingarm was dissasembled and a multitude of parts were pitched. Including the axle and swingarm pivot bolt. Sigh, I cannot believe the previous owner was allowed to own a bike at all. At this time Endo is still waiting for parts to reassemble his swingarm.

After that came the carbs.... hours and hours of carbs. Carbs carbs and more carbs. And you know I'm not talking about the good kind that comes in potato chips. No, cleaning and recleaning that four bank, then syncing them and adjusting floats so badly out of alignment I personally cannot believe it even ran.

It's been three weeks you'd think we'd have
swing arm bushings and bearings in by now,
but no.

Shiney clean carbs installed. Not pictured 3 quarts of elbow grease used in reassembly.

At about this time the fighter build-off was announced and Endo decided to participate. After reading my blog (link in sig :D shameless self promotion) he asked if I would consider writing it for him. Of course I agreed. So here we are.

Bike to date. Note the cool coolant bottle.

The project name itself was a major hang up. I originally proposed and argued valiantly for Project Passmark, as much of the work was to be done in class, but this was quickly vetoed. Project Endo-lution was proposed but dropped because of the vagueness of the name. Project Endo-volution was just stupid. Then one night whilst surfing the net we bumped into an old old old pic of a TIE Fighter pilot's helmet and inspiration struck.

The brainchild of Endo Project Darkside: ZX6E was born.

Current Mods:
Front, sides and lower fairing removed
Can shortened
Acerbis Headlight installed
Harley sportster fork signal lights
Custom Coolant Bottle
R6 Subframe and seat unit (with mini indicators and undertail eliminator) test fitted

It should be mentioned the above work was done prior to Endo arriving up North (Aug 18th)