My Cafe racer project

twowheelinjim · Posted: May 29, 2008, 1:18 am Post subject: My Cafe racer project

Good evening all, after many years of planning, sketching, day dreaming, I have finally aquired a 75' xs 650 to begin my project. After getting the bike home, she was stripped to bare bones. I began by blasting the frame, and cutting off all the unnessesary brackets. First on the to-do list is getting the engine top end rebuilt. Next is fitting all the parts I have been secretly hording. I found a set of clip-ons that will be used instead of the usual clubmans. The top triple clamp to me looks terrible in this configuration. I opted to make my own out of a piece of 1" thick aluminum stock. It looks a little boring right now, but now I don't have all those empty holes to stare at. A simple aftermarket spedometer with a bracket will be attached later. I found a suzuki titan 500 gas tank. It's shape is remenesent of a manx norton tank. Mounting it will be a challenge. After the motor goes back in the frame, I'll start figuring where it will be resting. I thought aluminum motor mounts would be lighter, but I got a bit carried away in my design. My new ones look better, but they are just as heavy. While everything was getting prepared, I made some rearsets. Here's a few pictures of the madness so far20parts/Picture031.jpg[/IMG][/img][img]

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And finally, the frame. It got a bit rusty because I forgot it outside for a few weeks. Time to reblast it.[img]

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pumps · Posted: May 29, 2008, 8:44 am Post subject: Re: My Cafe racer project

You are braver than me my friend!

royfisk · Posted: May 29, 2008, 8:44 am Post subject: Re: My Cafe racer project

nice start, have you got a milling machine? Those are some nice parts you made up there.

Finksies · Posted: May 29, 2008, 9:48 am Post subject: Re: My Cafe racer project

Lookin sweet, Nice work so far.

twowheelinjim · Posted: May 30, 2008, 12:01 am Post subject: Re: My Cafe racer project

I got a mill and a small lathe. I'm a machinist by trade, and don't mind bringing work home. I started a good set up by buying machinery, a welder, drill press. Next on the list will be a belt sander, and some grinders. I haven't found a decent compressor though. The last one I found had bondo patches on the rusted portions; an explosion waiting to happen. The jackass trying to sell it should have his butt whooped.

royfisk · Posted: May 30, 2008, 2:56 pm Post subject: Re: My Cafe racer project

pretty hard to beat northern hydraulics prices on Ingersoll rand 5 horse compressors.

Cooltouch · Posted: May 31, 2008, 7:53 pm Post subject: Re: My Cafe racer project

Hey Jim,

I have a mill and a lathe also -- took a year-long class in how to run them, but I'm not a machinist, although I do use them regularly, especially the mill. I'm curious about the top triple tree you made. How did you go about cutting the slots? Make a jig for the mill and then use a cutting wheel? Or did you just use an end mill and take off a little bit at a time? Or?

Best,

ichael

twowheelinjim · Posted: June 1, 2008, 3:39 pm Post subject: Re: My Cafe racer project

I originally started with with a cutting wheel, and the part angled in the vise. But unfortunately, the blade shattered. I then put the part back into it's jig, and programed the two linear moves using a 1/8" endmill. I have come up with a different shape for the triple clamp, so I may not be using the one pictured. After looking at some vintage triple clamps, I would like to add a more bulbious design. The new design will also incorporate spacing for my clip ons. If someone would like to experiment with the triple clamp in the picture, shoot me a PM.

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