Welded tank

A milestone! The tank was finally welded by a professional welders school into a desired shape.

Prior to to welding, the 0,7 mm metal sheets (the original thickness) were cut and formed while clamped in a plain vice. The former welding method was intended to be brass or silver soldering, in the end it was MAG, if I am not wrong. An industrial-type laser welding which may have lead to a best results was unfortunately out of reach.

Well, due to the small thickness and a high temperature, the sheets depressed around the seams, but the actual form is attained and the tank copies the curve of the frame. Anyway, the finalisation opens a space for working with metallic resin for which I am already looking forward. Subsequently, the frame was wrapped with a protective scotch paper and the tank seated well during the first check.

 The two pieces of fabricated sheets on each side

 welded workpiece below

The round corners will be welded soon as well

             

Brake hose set

Purchased steel braided brake lines with anodized dural banjos by Lightech. The fabrication of the fittings is good, the product is very light and goes well with the overall color scheme. The lenght is adjusted according to the genuine lines. The assembly is quite simple and just a few basic utensil is needed, like sharp pliers, round pliers, small screwdriver and spanner. Some useful how-to videos can be found on YT.

The joint attached to the lower yoke is bacically of no purpose here, it only serves as a make-ready for second braking disc fittings which can be found on "600"

Varia, misc., etc...

(Probably) the last dose of new chromed parts - shift gear, exhaust rings, various screws - mostly from the engine covers 

                                 Spacer ring for rear brake pedal, made of brass

The battle for the tank still goes on...it was cut off again as the previous attempt proved to be unsuccesful -  the left and right side closed inward like an envelope during the welding, which prevented the tank from being installed on the frame...This time, the inward sides were welded solely, first.

Auxillary frame should help maintain an accurate distance 17 cm during welding

                     Cardboard model to help determine the proper shape of the tank

                                                 
                                                     New Sunstar rear sprocket 

Front fender & rear tail cover pearl white paintjob

                                                    Covered with the clear coat

Braking elements

As I was dissatisfied with the quality of seals by the major aftermarket parts provider, I eventually decided to buy genuine Yamaha ones. The problem was with the dust seals which tend to splitting while the piston had been installed. OEM is triple times more expensive, however incomparably better. And that's that.

Previously used brake pads in a fairly good condition

Brake caliper pistons & seals

New braking elements - I ordered stainless steel pistons in one metal fabrication shop nearby. It cost me 700 CZK (4 in total), a very fair price for replacement which is even better than the genuine parts - plain steel and chrome plated pistons.

Full set

Caliper seals 

Bleeding screws - stainless M8 for front brake and two dural M7 screws from Lightech for rear 

Before coating, the inner grooves were full of oxidated alloy - I've scratch the corrosion carefully out and polished the space with aluminium polish paste. The seals got to seat securely in its grooves

Application of thick layer of vaseline

Last but not least, here we have a great replica of genuine stickers for rear fender cover - now unavailable - made according to the image found on web and cut from a golden foil on plotter. 

Many thanks for creating the graphical draft, M. Sz!