Author Topic: Reproduction K cap  (Read 6459 times)

0 Members and 1 Guest are viewing this topic.

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Reproduction K cap
« on: June 16, 2019, 08:10:49 AM »
The K is the exact size and shape as the original and is raised.  $70 shipped (more outside of the USA)
« Last Edit: June 18, 2019, 08:05:24 AM by gixxer6 »

DougKauer

  • Sr. Member
  • ****
  • Posts: 282
Re: Reproduction K cap
« Reply #1 on: June 16, 2019, 04:19:51 PM »
So the cap fit all Kawasaki snowmobiles?

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #2 on: June 16, 2019, 05:52:55 PM »
Im not familiar with some of the Kawasaki models, but I know they will fit Interceptors, Invaders, Intruders, and LTDs. 

mswyka

  • Hero Member
  • *****
  • Posts: 1757
Re: Reproduction K cap
« Reply #3 on: June 17, 2019, 09:23:02 AM »
Remarkable.  What plastic did you use?

My sense is that the original caps, and the original fuel tanks, cracked because of poor resin/resin processing additive choice.  We saw this phenomena in the polyethylene manufactured in the 80's.  In our industry we call it Environmental Stress Crack - where the material has a brittle failure before there is any elongation.  It was a function of multiple factors including high molecular weight resin (0.948 and above) and the use of processing agents like sodium bicarbonate.  The industry has switched to lower molecular weight resins, beefier antioxidant packages, and elimination of the sodium bicarbonate.
Intruders:  1978, 1979, 1981 Custom (Pink)
Invaders:   1980 440
Projects:    1981 Invader 440, 1982 Intruder 440

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #4 on: June 17, 2019, 09:50:34 AM »
These are a customized aftermarket cap.  I am unsure what plastic the aftermarket company used originally.  I considered at 3 options: 

1.  Remolding a cap with the "K", this would be best for high volume (tens of thousands) but I suspect only a few hundred at the most would sell even if priced low.  The initial cost of creating a mold cost in the neighborhood of $10,000. 
2.  3D printing new caps.  This was a little more feasible than option #1, but the cost of having a 3D image of the cap created would have been quite a bit.  The added cost of having them printed with a high enough quality printer would have made them extremely expensive. 
3.  Customizing an existing aftermarket cap.  This was the only feasible option, and being they are such low quantities the price still ends up being higher than most would like. 

IF I had enough interest in these to make larger quantities the price would come down some.  But they will never be as inexpensive as the $15-$20 kimpex caps. 

I always thought that the original "K" caps cracked because guys would crank the cap too tight in an attempt to align the "K".  I suppose they could be made of a slightly different material, but I doubt it.  I don't think there were many options in plastic material types (at least ones that will withstand gas) back then. 
« Last Edit: July 17, 2019, 10:57:34 AM by gixxer6 »

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #5 on: June 18, 2019, 08:06:46 AM »
Cost of materials was lower than expected so I was able to drop the price from $75 down to $70 shipped.   :)

DougKauer

  • Sr. Member
  • ****
  • Posts: 282
Re: Reproduction K cap
« Reply #6 on: June 18, 2019, 06:00:47 PM »
This might be the reason to why the filler necks cracked to. After looking at a few, Kawasaki should of made them thicker. Some crack and some do not. But I think you are right guys would tighten them too much.

DougKauer

  • Sr. Member
  • ****
  • Posts: 282
Re: Reproduction K cap
« Reply #7 on: June 20, 2019, 06:26:04 PM »
Put me in for one.

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #8 on: June 21, 2019, 06:46:54 AM »
Put me in for one.

Will do.  Thanks Doug. 

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #9 on: July 17, 2019, 11:09:41 AM »
I started out making these in a very small quantity, 11 with 3 of them for my own sleds.  At this quantity I can sell them for $70 w/ free shipping (as noted above).  I looked at doing these in a larger quantity.  Making a batch of 50 I could price them at $45 each PLUS shipping cost.  So far I've had very little interest in them, but have one that committed to 4 or 5 if the price were reduced to $45.  IF I can get enough interest I will move forward with a batch of 50.  Anyone? 

Dandb7

  • Sr. Member
  • ****
  • Posts: 293
Re: Reproduction K cap
« Reply #10 on: July 18, 2019, 05:30:29 AM »
Put me in for one also !
1982 Kawasaki Interceptor 550 #558
1979 Kawasaki Drifter 440
1989 Arctic Cat Pantera 440
2012 Arctic Cat F1100 Turbo 50th Anniversary 2015 Arctic Cat Lynx 2000

DougKauer

  • Sr. Member
  • ****
  • Posts: 282
Re: Reproduction K cap
« Reply #11 on: July 18, 2019, 10:03:20 PM »
Guys when you see these you will want more. Tom did a awesome job with these. I bought two and I can personally tell you I love them. I am the one who wants more of them. I'm going to use them on my two sleds when I take them to the Nationals in August.

750-h2

  • Jr. Member
  • **
  • Posts: 53
Re: Reproduction K cap
« Reply #12 on: July 19, 2019, 08:26:58 AM »
Did the Interceptor's come with the K caps? My low mileage Interceptor had the flat cap when I purchased it from the original owner?

gixxer6

  • Hero Member
  • *****
  • Posts: 1555
Re: Reproduction K cap
« Reply #13 on: July 19, 2019, 10:02:07 AM »
Thanks Doug! 

750,  I am unsure which models came with the "K" caps...I thought it was the earlier models that came with them until they realized that guys would crank them down too tight to make the K straight with the sled and crack the caps and filler necks?  Maybe someone can confirm this?  What I do know, is that they are EXTREMELY rare...I have been at this for 15 years and have only ever seen 4 of them, 3 of which were cracked, the 1 that wasn't happened to be a NOS one that I came across (and will be going on #366  8)). 

DarthInvader

  • Newbie
  • *
  • Posts: 16
Re: Reproduction K cap
« Reply #14 on: September 09, 2019, 10:04:25 PM »
I'd be interested in several.  Also, are they missing the circular ridge around the periphery, that the original has? 

And if so, could that be incorporated? 

Thanks!
« Last Edit: September 09, 2019, 10:25:28 PM by DarthInvader »