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xs650 > > Custom Work: Chop, Bob, Cafe and Flattracker - Streettracker > > Cafe Racer > > Cafe Racer project in Australia |
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: October 15, 2008, 3:13 am Post subject: Re: Cafe Racer project in Australia |
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At the moment I'm working on the tank. So far I've shaped one side panel and am about halfway through the the other side.
There is still alot of work in finishing them to get a full polish. It's good fun though. I've been looking up site's on armoury. Some amazing work there, and some handy tips.
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ABSINTHE Full Member
Joined: Nov 05, 2008 Posts: 53
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Posted: November 12, 2008, 7:09 am Post subject: Re: Cafe Racer project in Australia |
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what top triple clamp are you using is it a standard one with the holes in the top or something else thanx a lot
_________________ IN BENZIN VERITAS |
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: November 30, 2008, 4:15 am Post subject: Re: Cafe Racer project in Australia |
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Hi Absinthe, The top clamp is just the standard with all the bits off and polished.
I haven't done much on the project for a couple of weeks.
I've got a broken foot thanks to a wheel rim that came off the back of an oncoming truck. I was doing about 120 kph and I guess he was doing about 100kph. Suddenly this steel wheel rim bounced up from behind it, and came straight for me. I locked up the bike (SV650 Suzuki) , it got a little crossed up then wham the rim hit me in the right foot. It ripped open my boot, smashed my second toe (bits of bone sticking out) and broke a bone in my ankle. Fortunately I didn't come off. I had to ride about 25 KM to get to the local hospital. They've put a wire in the toe to hold it together while it heals.
I guess I'm lucky it didn't hit me in the chest or head.Oh and the bike didn't get a scratch. Can you believe it???
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xsjohn Full Member
Joined: Jul 30, 2006 Posts: 5857 Location: North Carolina USSA
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Posted: November 30, 2008, 1:00 pm Post subject: Re: Cafe Racer project in Australia |
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Think my big toe just started to hurt again where I hit it with a hatchet when I was a kid................
xsjohn
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xsleo Full Member
Joined: Oct 28, 2007 Posts: 1528 Location: Earlville NY
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Posted: November 30, 2008, 4:21 pm Post subject: Re: Cafe Racer project in Australia |
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on your brakes, can you make a bracket that bolts to the fork, then your calipers bolt to the bracket. i have seen this done on other bikes. when building the bracket you can build in whatever offset you need.
_________________ "You live more in five minutes on a bike than most people do in there whole life"
'75 XS650B with a 79 dual disc front end, rear disk brake, Chrysler reg, Radio Shack rect, LED tail/ brake and turn signals. |
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pumps 650Rider Supporter
Joined: May 29, 2007 Posts: 1993 Location: Kansas City, Missouri, U.S.A.- 1977 XS650 "D" Standard
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Posted: November 30, 2008, 8:42 pm Post subject: Re: Cafe Racer project in Australia |
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Razar, go buy a lottery ticket eh? Sounds painful though....
_________________ You don't HAVE to be crazy to run into burning buildings, but it HELPS!
On an XS you won't pass yourself on the road everyday.
My Bikes |
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scalejockey Full Member
Joined: Oct 26, 2008 Posts: 39 Location: Boise Id.
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Posted: December 7, 2008, 7:45 pm Post subject: Re: Cafe Racer project in Australia |
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EEEESH! Man that was a close call!
Iv'e busted up feet at different times,IT REALLY HURTS!
Keep the updates coming when your back off the pain meds.
_________________ Fix it till it's broke! |
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: January 27, 2009, 1:34 am Post subject: Re: Cafe Racer project in Australia |
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Hi guys, I'm back. I bought the lottery ticket (several actually) but it would apear that I have used up my allocation of luck for the time being. The foot, however, is back to being a useful addition to my leg. Ocasionally though, it has a mind not to do exactly as it's told
Xsleo, the way I'm doing the brakes is the way you suggest. The problem has been to get enough space between the disc and the spokes for the back of the caliper. You can fit a spacer to move the disc out but there is a limit before the discs hit the forks.
I've finally finished putting the tank together, though I'm yet to pressure test the welding, which could be an interesting exercise. This has been a steep learning curve, and some of the welding started out pretty ordinary. Also, as you can see I have not sanded or polished it yet.
I want to get on with the hold down strap and mounting. Once they're done and the steering stops altered to limit the turn of the forks a little, so that the forks don't contact the front of the tank, the frame will be off to get blasted and powder coated.
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JeffM Full Member
Joined: May 07, 2008 Posts: 285 Location: Victoria, BC, Canada
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Posted: January 27, 2009, 1:55 am Post subject: Re: Cafe Racer project in Australia |
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Wow ... just beautiful!
Nice lines and good work. Filler neck has a nice molded in look.
Jeff
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 15, 2009, 10:17 pm Post subject: Re: Cafe Racer project in Australia |
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SHIiiiiiiTT!!!!
(can I say that here?)
Just about finished assembling the bottom end of the motor. Looking nice, all bead blasted clean, gaskets gooed, copper washers and stainless nuts and bolts shiney and new. Gear selector stuff all in place and adjusted. I'm just about to assemble all the gears in the right casing. Following the book.
I lay out the gears etc on the bench. Hang on? What's this shaft? There's no shaft in the book. Ahh the joys of assembling things that have sat in boxes for a year. It's the shaft and gears that come from the starter motor. Unfortunately the gear that engages the starter has to be fitted from the inside. s***!! I'm sitting having a quiet cup of tea then I will go and pull it down. s***!!
Oh yes, Thanks Jeff.
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Finksies Full Member
Joined: Jan 26, 2008 Posts: 178 Location: Windham, NH
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Posted: February 15, 2009, 10:46 pm Post subject: Re: Cafe Racer project in Australia |
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Wow just found this thread. Really nice work. What kinda welder are u using? Did u build ur english wheel frame and just buy the dies? Very cool.
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ABSINTHE Full Member
Joined: Nov 05, 2008 Posts: 53
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Posted: February 19, 2009, 7:16 pm Post subject: Re: Cafe Racer project in Australia |
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looking good hope your foot will be ok i havet been on iv been on holidays
_________________ IN BENZIN VERITAS |
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Retiredgentleman 650Rider Supporter
Joined: Mar 03, 2007 Posts: 2258 Location: Calgary, Alberta 1978 XS650 SE
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Posted: February 19, 2009, 8:13 pm Post subject: Re: Cafe Racer project in Australia |
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Razar;
I really like the craftmanship you are putting into your project. The seat looks great, and that tank will be a thing of beauty. The finished bike will be a real eye catcher.
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 19, 2009, 10:24 pm Post subject: Re: Cafe Racer project in Australia |
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Thanks for the feedback.
y welder is an Allmax 200P AC/DA Tig and stick. A better quality cheap Chinese inverter number. Bought off Ebay.
I've been doing the engine assembly 3 step. 2 steps forward 1 step back etc. I fixed my problem from the previous post. Put the pistons on and the barrel to discover that the cam chain didn't go through the tensioner like it should. I should add here that I joined the chain prior to assembly as I read somewhere that you can slip the cam into it then put on the cam bearings making the whole thing of joining the chain easier. Well I forgot to break open the tensioner mount a feed the chain through it. More profanity followed. So off with the barrels and tensioner etc do the job , back together. The barrels move, oops forgot a dowel at the base. Fortunately I just had to raise the barrels up and unscrew the stud and slip it into place. Easy fix.
I'm presently porting the head.
From here on in in this post It will mostly be assembly as most of the bits and pieces are done. I'll list the mods etc as I go along, and post fairly detailed pics.
Pic 1
Frame. Powder coated satin black. All unnecessary stuff has been cut off. Footpeg mounts, center stand batterybox and air cleaner tabs etc, Tank rubber locators.
roller bearings in steering head. Bronze bushes in swingarm and new spindle and sleeve. Cheap shocks (which will be replaced with good ones when bike is finished)
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Barbara Full Member
Joined: Feb 17, 2008 Posts: 812 Location: Washington State
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Posted: February 19, 2009, 11:11 pm Post subject: Re: Cafe Racer project in Australia |
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Everything is really impressive, but that tank....that big old tank sitting above the engine, with those Dunstall-patterned pipes looks SO MUCH like a production-racing Norton 650SS that I just drool!
Love that tank!
_________________ Barb
Jaelith the XS650 with sidecar
Britney the BSA
Gemini the BSA
Baby B. the BSA
Big John the BSA
The unnamed Triumph T-140
and the 1979 XS650....with "potential"
illie the 1980 airhead BMW |
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 21, 2009, 12:23 am Post subject: Re: Cafe Racer project in Australia |
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And one more.
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 22, 2009, 4:01 am Post subject: Re: Cafe Racer project in Australia |
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RIPPIN INTO IT!!
Lapped the valves and fitted them.Placed the head on the barrels.
I'm also stripping down the front end for another polish and final assembly.
The photo's are ; clipons from a FZR 250 headlight mounts stainless steel I made.
Front guard polished aluminium also made by me.
The engine so far
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Last edited by Razar on March 2, 2009, 10:12 pm; edited 1 time in total |
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yamaman Support Staff
Joined: Jan 04, 2007 Posts: 1638 Location: Perth Western Australia
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Posted: February 22, 2009, 7:39 am Post subject: Re: Cafe Racer project in Australia |
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Thats going to be a fine motorcycle one day very soon!
Hope your foots getting better & you got the # of that truck!
Cheers
_________________ Its not enough to have an aim in life, you have to pull the trigger! |
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cretin75xs650 Full Member
Joined: Dec 24, 2008 Posts: 99
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Posted: February 23, 2009, 9:15 am Post subject: Re: Cafe Racer project in Australia |
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Nice build Razar, I've been watching your build on the Ton...Keep the pics coming.
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 26, 2009, 1:08 am Post subject: Re: Cafe Racer project in Australia |
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Thanks guy's and the foot is almost back to normal.
I've been finishing off the motor, doing little things like polishing the dip stick cap etc. The front end is back on the frame to about the same stage as earlier pics. I have to clean up my master cylinder before I finish the brakes. Just about ready to put the engine back in the frame.
I thought that some of you maybe interested in these. My lower tripple has no lips for gaters so I made these up to clamp on the stancheons. I call them Gator Lips.
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TeeCat Full Member
Joined: Aug 21, 2007 Posts: 1120 Location: Central Maryland
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Posted: February 26, 2009, 9:53 am Post subject: Re: Cafe Racer project in Australia |
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Man... WHERE did you get your skills??!! Are you just flying by the seat of your pants, or do you have a mechanical background?
VERY nice!
TC
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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Posted: February 26, 2009, 7:38 pm Post subject: Re: Cafe Racer project in Australia |
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Thanks Tee Cat.
I'm self taught on all this. Most of these bits and pieces are my first attempt. It's the first bike I've worked on. Mind you, I'm 53 and I've been building and making stuff all my life, so I guess it all sort of adds up to a basic ability. I think the main thing though is that I'm not scared to have a go.
The photo above is garbage. Here's another one
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Razar Full Member
Joined: Jul 03, 2008 Posts: 103 Location: North Coast New South Wales Australia
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