Zephyr 750 cafe-roadster. Seat&Tail.

Okay. Here I have some update about Zephyr 750 Cafe-Roadster kit project, a bit out of date for now, but I had no time to write this text earlier.

This chapter is about tail and seat base. Those who may had taken a look on previous parts of Zephyr story saw that I had models and know that I want not only one set of seat and tail, but the ability to replicate them. So I needed a mold for each part.

In this case I had to do next steps:

• to check symmetry
• to optimize parts for fiberglass manufacturing
• to workout all tail mounting points and seat lock features
• to make part’s models surfaces as perfect as possible.

 And that was a work which took a lot of time and efforts. Many evenings I spent with putty, sandpaper, soldering-iron, iron net and pieces of plastic. Finally I made my best with tail:

All tail features were workout and checked, then rechecked again and only after that tail was primed:

And then painted and coated with varnish:

The requirements to seat base surface were less exacting, but work wasn’t less mere. There was a initial “Frankenstein”, I welded from parts of original one and pieces of plastic.

So I had to optimize it: cut off some details, add another and so on. A lot of putty and sand paper work again. And of course, reinforcing and so on…

After checking it was also primed:

And then coated with varnish:

After all above-mentioned ordeal was performed, the tail and the seat models where ready to mold making.

To be continued.

by