The $100 Wonder: Cafe build....

scotts · Posted: February 2, 2008, 4:44 pm Post subject: The $100 Wonder: Cafe build....

Some of you may have read my threads on the "$100 Wonder" that I picked up off Craigslist and got running.
Well, the project has progressed well past the "get it running" phase and is now in the "make it look cool" phase, so I thought I'd start a thread dedicated to the build-up of my cafe racer.
Plans are for an XS750 tank, Omars narrow fender, Clubmans, fork gaitors, etc.
Here's a pic to remind you all what I started with:

scotts

After fixing the kickstart and electric start, cleaning the carbs and changing the plugs, we got it running. I had to replace a few oil seals and gaskets, too. It's still not bone dry, but 90% better than it was. I was able to take it for a spin around the neighborhood and it feels strong and runs well.
Now that it's running OK, we started modifying it. I mounted and XS750 tank and mocked up the Omars seat. I'm waiting on a buddy of mine to build me a bracket/brace for the rear of the seat and then it will be done. NOTE: The Omars seat has to be moved back to clear the XS750 tank just far enough to make the usual mounting points unusable!
Here's a pic with the forks removed (more on that later) and the seat and tank mocked up:

scotts

Today, we installed the copper head washers from MikesXS and retorqued the lower headstuds (still chasing the last few drips). We also did the breather mod and installed a new filter. I'll be running velocity stacks on this bike, so no factory breather hook-up. Did you notice the stacks in the pic above?

scotts

I also taped up the bike in preperation for spray-bombing the frame. There'll be some engine paint/detail coming up soon, too.

scotts

Got the cylinders paint detailed today using Dupli-Color high temp engine paint.

pumps

I like your work. I have always like the 750 tanks too. What gave you the idea to put one on a 650? Was there some inspirational picture? I like the..I don't know the word to describe the 750 tank shape..the dimples? scallops?. Any way I like the look.

KYLEPRESTON

LOOKS LIKE SOMEONE HAS BEEN SHOPPING AT MFGSUPPLY FOR THOSE STACKS GOOD DEAL. MINE WORK GREAT AND YOU CAN'T BEAT THERE PRICE.

LOOKING GOOD MAN

scotts

Thanks all! I had seen bikes with the XS750 tank and thought they looked cool. The scalloped sides also jibes with the classic cafe' racer tank look without having one hand-hammered out of aluminum.
Kyle...can you tell me a little bit about your battery box wrap/cover thingy? I've got to come up with some sort of side covers for this bike. I have a few ideas, but they're all in the planning stages right now.

KYLEPRESTON

built it out of stainless steel. pop rivit together. the stainless is the covering for a fridge. just unbolt and you have a nice workable piece of metal. I am working on reworking it currently. so it's off the bike for now. but I left one side to bolt on and it uses the stock mounts in the front to hold it. I am reworking because I got the stacks and changed from the pods I need more breathing room. the pods breath 360 and the stacks are back breathers. the tx frame is shorter in the battery area than the newer frames so little less room to work with. I am hoping to rework my seat at some point and relocate all but the battery under there. then I will have loads of room to play with.
if you need more pics let me know be happy to post.

cheers

scotts

Been working on the permanent mounts for the Omars fender. Here's a shot of the front bracket. I have some rubber washers/spacers that will go between it and the frame when it's all bolted down.

scotts

And for the rear, I had a buddy weld on a plate across the frame. Using the XS750 tank caused everything to be pushed back an inch or two. Here, it's all done except drilling two holes for the well-nuts. I need a larger drill bit to finish...hopefully tomorrow...and then I can finish painting the frame.

scotts

We also got the rear turn signals and tail light mounted. The turn signals are wired in. I still have some thinkin' and wire tracing to do in order to get the tail light wired up. (Sure wish my camera took better pics in the garage)

scotts

I'm still trying to decide on a paint color. Here's another XS750 tank I have; black with a graphite insert. The insert is reflective and looks cool, I think. My significant other is quick to remind me that I already have a black bike.
I considered silver, but I'm afraid the bike will get a little too "washed out" with the chrome fenders and polished engine cases.
Any suggestions?

KYLEPRESTON

I am partial to a cream color. with gold pin stripe. What about a dark brown.

scotts

Been chipping away at this project. I paint detailed the controls....

scotts

Installed rear shocks sans reflectors and ground off the front reflectors...

scotts

And detailed the front wheel. First, I polished it with fine sandpaper, Scotchbrite pads and 000 steel wool and Blue Lightning metal polish until I LITERALLY had blisters on my fingers.
Then I carefully masked it up with blue painters tape and spray bombed it flat black.
aybe not a show finish, but it came out darn good for a total cost of about $2. I'll get to the back wheel soon....

TeeCat

Wow... that's really coming along! I can't wait to see all the bits come together! Smile

TC

scotts

Today, I dropped off the front wheel for a new tire. I had the shop press in the bearings for me while they had it.
I also prepped the tank/seat/headlight bucket for paint. I sanded the seat and bucket with 400 grit and then cleaned them with denatured alcohol.
The tank was a little more involved. Since it had the factory stickers and clearcoat on it I had to use aircraft stripper. Here's a shot of the "during" and what the tank looks like after rinsing and sanding with 400 grit.

scotts

Got the front end back together today. We pressed in new tapered bearings in the steering head, installed the polished forks/fender/fork brace and mounted up the front wheel with a fresh tire and new wheel bearings.
You can also see the Clubman bars in the second pic.

scotts

I dropped the tank, seat and headlight bucket off at the painters today to be primed. Then it was out to the garage to work on the controls.
I installed new stickers on the controls and got everything mounted/mocked up on the Clubman bars. We installed the Moto GP grips, too. I'll make the final adjustments and bolt them down for good when I get the seat and tank back on the bike. We also bled the front brakes today.

scotts

Then it was time for a little bling! We put on the polished valve covers and left side engine cover. We also mocked up the exhaust. We have to make/modify a couple of mounting brackets before we can bolt it down for good.
I have the right side cover to match...just waiting til I get a chance to drain the oil and get it on there.

scotts

One more shot of the engine detail.

Cooltouch

Hey Scott,

That aluminum sure is shiny! Did you follow the same regimen for polishing the motor's bits as you did the wheels? If not, what'd you do to get it so shiny?

I'm always looking for better ways to polish aluminum. Seems like no matter which way I try it just requires a lot of elbow grease.

Best,

ichael

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Yamaha xs650