Norton 880 long-term project

You'd better get a comfortable couch and a LARGE bag of pretzels, it's a year away more than likely.

I just got an '03 Kawasaki ZRX project I need to replace a bunch of wrecked stuff on, so my son and I can do a 1,000 mile iron butt ride on "fraternal twin" ZRXs.

...not to mention the 4 client restorations already underway!
 
Just received the one-off hand built monoshock rear end setup from Kenny Dreer. This little jewel is quite the trick bit.

Norton 880 long-term project
 
Beautiful Piece of Work

That is a beautiful piece of work. Was that the design for the Dreer Nortons?
 
One of the pre-production prototype bikes had the monoshock rear end, the one in the photos I posted earlier; those photos went around the web early on, before the actual running test bikes started being shown with standard dual shocks.
 
Kenny recently sent me a couple more pix of the 951 prototype, including this rare photo of the Left side, I don't think this one was ever published-

Norton 880 long-term project


Picture upside-down forks and classic wire spoke wheels...
 
Preliminary mockup; please consider the fact that I don't yet have the shock mountings fabricated, don't have the proper adjustable link
on the shock pivot arm, and don't have the rear axle adjuster blocks that slide into the box section swingarm.

Norton 880 long-term project


Front tire will be a bit taller profile on wire spoke wheel, rear tire will be a bit shorter profile on matching wheel with rear disc.
 
I have a UJM wire spoke, dual disc, front wheel of unknown origin.

However, I'm searching for a better match as this one will need shimming on the discs to align with the calipers on the upside-down forks, and the discs are solid, not drilled and not floating. I'd really like full floaters.
 
A buddy is working with an early GoldWing hub that accepts some Kawasaki semi-floating rotors. You might check out something like that.
 
75-77 Goldwings do have strong hubs and are quite cheap. Seems like a friend told me they might also be the same as 750 Hondas but I'm not sure about that.
 
Who has a nice spare crank?

I'd like to have a really nice crank for this project, perhaps with a billet flywheel. Something that is KNOWN to be trusty, maybe already magnafluxed and balanced, etc.

What have now is a stock 750 c rank which SHOULD be okay in non-racing application, but i'd like to go a step or two better.

Anyone got one gathering dust?
 
Got a much nicer shock and worked out the required geometry to fabricate the upper shock mounting on the frame. It will involve two plates hung underneath the main tube, just behind the web plate aft of the carbs. I'll also add a bit of triangulation on the front side of the web to gusset the stressed section.

Norton 880 long-term project


Norton 880 long-term project
 
Perfect fit on the mounting plates, just need study the optimal end length for maximum adjustability in the intermediate link, then weld them up.

Norton 880 long-term project


Chain adjustment axle blocks are ALMOST done. I didn't notice he drilled the axle holes too small!

Norton 880 long-term project
 
Monoshock mount fabrication & installation complete. Same center of axle to center of shock top mount spacing as standard,
with the axle & adjustable link at mid position.

Norton 880 long-term project


The powdercoating held up quite well to the heat from welding (lowest amperage setting to maintain good penetration and strong bead).
Some touchup paint will hide the scars and there you have it.
 
Here's the rear brake anchor point, not as clean but I'll dress it up.

Norton 880 long-term project


Now do design a new axle, stub axle and spacers, then have the machinist do 'em up.
 
Play money has pretty much dried up, but there are actually lots of little things I can do over the winter that won't cost much at all; here's a short list that'll keep me busy for a while:

-clean & prep all the engine parts I already have
-touchup paint the frame & swingarm where I've welded
-re-paint the cylinders
-re-lace the OEM rear hub onto a clean 18" aluminum rim that I have
-complete the mods & fit up the yokes to get proper range of motion
-modify & fit up the standard bar risers
-mount all the foot & hand controls
-fabricate some custom instrument mounts (maybe integrate them with the handlebar mounts?)
-fabricate a battery mounting setup that hides well
-strip down a good wiring harness, modify it for my use, then re-wrap it to look nice
-carefully dress up (Dremel cut) the OEM right crankcase half to match the custom built left half
-carefully recess the backside of the OEM oil tank to clear the monoshock (only need 1/4" or so)
-fabricate a custom headlight mount setup (has to mount to the large diameter USD forks)
-pull the ARD mini-magneto from the Combat & replace with a Sparx setup < that one will cost a few $$

PLENTY to stay busy till the funds get flowing again.
 
It's beautiful work you are doing on her. It's not like you have to have a schedule on such a major project.
I hope to get some time to work on my bike after this week as I still have three train cars to tear down and put away before I can turn my hand to my stuff.
 
I like reading these reports.
Keep them coming 8)
 
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