Zephyr 550 cafe-racer kit. Moulds and first parts.

And here we go: moulds for  Kawasaki Zephyr 400-550 cafe-racer kit are ready, as well as the first two sets of real fibreglass parts.  And even if it took longer than I was expecting (and much longer than I  dreaded to imagine), results are quite impressive. Here is mould for fibreglass seat base.

Kawasaki Zephyr 550 cafe-racer kit by Gazzz Garage: seat base mould Kawasaki Zephyr 550 cafe-racer kit by Gazzz Garage: seat base moldIts likeness to broad-brim hat is caused by the reason that seat bases have to be vacuum moulded, therefore mould was optimized for such manufacturing.

Mould for tail may look less impressive, but in fact its two-piece mould for a  part of a quite complicated form, therefore, both its parts have to fit neatly.

Kawasaki Zephyr 550 cafe-racer kit by Gazzz Garage: tail mould Kawasaki Zephyr 550 cafe-racer kit by Gazzz Garage: tail mold Kawasaki Zephyr 550 cafe-racer kit by Gazzz Garage: tail mouldFirst two sets of parts (pre-ordered) are also ready. In fact these two seat bases are already in the upholstery shop and their cushioning is finished. I hope to get both seats ready next week.  My aim is to keep the same seat (and therefore kit) design even as seat bases of 550 and 750 Zephyrs have surprisingly different structures.

Kawasaki Zephyr 550 cafe-racer kit: seat base Kawasaki Zephyr 550 cafe-racer kit: seat baseAnd since only recently I finished working on these two first tails, I couldn’t wait to receive ready seats and  take a first look at my embodied idea: first bolt-on cafe-racer kit installed on Kawasaki Zephyr 400-550.

Kawasaki Zephyr 550 cafe-racer kit: tail Kawasaki Zephyr 550 cafe-racer kit: tail Kawasaki Zephyr 550 cafe-racer kit: tail Kawasaki Zephyr 550 cafe-racer kit: tail Kawasaki Zephyr 550 cafe-racer kit: tail

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