Thumper Club Forum
Technical => Project Progress => Topic started by: turkeyuk on July 09, 2009, 07:12:33 PM
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Hi all, ive been collecting bits n bobs for my cafe racer project for about a year now, other things always seem to take priority! (i know, i know, bikes should be at the top of the pecking order ;) but a missus, 2 kids, a recent house move & being self employed has dictated its progress so far!)
anyway i will post what pics i have got so far, its not a rolling chassis yest as im still looking for some trick wheels & a jmc swingarm would be nice. also wanted to fit adjustable forks & a fork brace.
Heres a mock up of chassis with Raask rearsets, supertrapp stainless pipes & an RS125 seat unit which will sit properly when the frame is cut down to accommodate it 8)
Frame will be shotblasted & powdercoated, all brackets & fastners are being zinc plated.
i havent decided on a colour yet but leaning towards black, black & more black!
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01460.jpg)
I have hagon or koni adjustable shocks & hagon progressive springs for it.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01461.jpg)
im still not sure whether to keep the pipes in the standard position or have them high up next to the seat unit?
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01462.jpg)
Inspecting my 500cc race engine with a view to increasing capacity to 600cc with a high comp forged piston i have or 650 dominator?
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01523.jpg)
40mm Dellorto Carb which will breathe through an MX style filter (no airbox)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01524.jpg)
Gas flowed head
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01525.jpg)
Cam lobes & centre bearing showing signs of wear so will have to get this sorted.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01527.jpg)
Any input or comments are appreciated ;) cheers, Paul.
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Bollocks that is more complete than any of my bikes.... ;D
R
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Can't wait to see the next instalment :)
GC
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Very promising .
Rob .
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Can't go wrong with black ;D proper motorcycle colour! 8) ;D ;)
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I'm VERY jelous of those supertrapp silencers !!....I know another XBR that would look great with those!
I take it that you've read the White Brothers GB500 hop up article from Cycleworld? you already look to have a lot of the stuff they used, just need the 600CC top end and WB cam. When you have it completed I'll have to pop over and have a look ;)
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no probs pop in when you are out this way steve, ive got a 600cc forged piston & barrel & a HRC cam for it although i havent seen the write up you mention i wouldnt mind a copy if you want to send me a link that would be cool, cheers ;)
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Try this. ;D
GB 500 Hop Up - cycleworld project (http://www.champsclock.com/gb500hu.htm)
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That looks like you've got the R&D valve springs installed, was that a modified cam?
I used the biggest K&N I could get in there for an air filter, dyno showed no restriction over an open intake. That was with a 40mm Dellorto.
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Try this. ;D
GB 500 Hop Up - cycleworld project (http://www.champsclock.com/gb500hu.htm)
Cheers steve, thanks for the link.
That looks like you've got the R&D valve springs installed, was that a modified cam?
I used the biggest K&N I could get in there for an air filter, dyno showed no restriction over an open intake. That was with a 40mm Dellorto.
Yeah i dont think the valve springs are standard, im not sure about the valves themselves though, the race engine came with a joy & megacycle cam but im not sure which one is fitted & also HRC cam, i have the HRC cam to go on instead as the lobes on this one are showing signs of wear as well as the journal in the centre. I will look into K&N's did you use a cone filter or one of the foam ones & did it clear the underside of the tank ok? mine has an elongated inlet stub?
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Managed to get some bits done over the weekend & this afternoon,
my future beach race bike (another project!) has been raped & pillaged for parts that wont be needed on it for this project & to help restore my roadbike.
Got standard forks & wheels for now to get it rolling & some koni adjustable shocks.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01536.jpg)
Here's whats left of the sand bike!!
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500/DSC01534.jpg)
just need to build up the mock up now will add some pics, then its all coming apart again for powdercoating, all fasteners zinc plated & engine striped rebuilt, vapour blasted & side cases powdercoated.
I'm not sure whether to go for gloss black on the side cases along with the fork legs & the rest of the chassis & bodywork for that mean & moody look?? I'm not too into polishing :P
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I used a round filter not a cone, I'll try and get a pic, it was a genuine K&N. I can't remember when I fitted it, originally I had an adapter about 3" long but I shortened that as far as I could and got a little more power throughout the rev range. No problem with the tank.
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Nice one thanks for that ;)
Managed to get some time on it this weekend between working on my roadbike. (the one lurking in the background).
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500/DSC01548.jpg)
The cam has left some of its metal on the centre bushing in the head, it looks like overheating caused by oil starvation probably from a blockage in the oilways.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01554.jpg)
I will hopefully be able to remove this without damaging the head & fit my new cam, it is a HRC spec cam grind I think by newman, it is engraved NM4
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01556.jpg)
I have also decided to use my dominator engine with the Venolia Forged hi comp oversize piston.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01557.jpg)
I am going to run it without an electric starter so can use my XBR generator cover. I will swap the generator & flywheel for the XBR one along with the XBR primary drive gears, it will have standard dommie crank & gear ratios.
I have an EBC clutch & new heavy duty clutch springs to go in it.
Can anyone confirm if i will encounter any problems using my xbr500 head on my dommie barrel?
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That cam looks all wrong for an XBR, is it a Dommie cam? The XBR head on a Dommie barrel will depend on the year of the Dommie engine, the Dommie crank that I have seems much wider and it doesn't look like the cam sprcket would line up. I was told that only the early engines share the same crankcase pattern.
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Yes its a dommie cam & an early dommie engine with kick start, the camchain all lines up no problems but the cam fouls the casting on the xbr head, i didnt realise this until i started to rebuild it this evening, i have two choices, get the cam & head repaired or gas flow this head for it which my race cam fits, im thinking a bit of porting is the easiest & cheapest option as i can do it myself by copying the port on the race head. ;)
ive got a slotted cam sprocket too for any necessary fine dialing.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01563.jpg)
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started a quick loose build up to check proportions & where everything will eventually fit.
still need to cut & shut seat rails, im going to use the original light & bracket mounting to try & keep it factory looking. The original lamp will be recessed into the back of the seat unit when ive got the profile right. Im also hoping to use the seat lock too so the seat unit can just be lifted off, probably be enough room for gloves & a disc lock too.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01570.jpg)
Ive utilized a standard battery mount for the oil tank, it will have the redundant tabs ground off.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01569.jpg)
i have another battery mount which will fit nicely under the seat which will also look factory & mount all the electrics together. I will possibly cut down a plastic undertray to keep everything out of the wet & muck.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01567.jpg)
Dominator engine coming together to check everything before being pulled down for vapour blasting & powder coating.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01565.jpg)
just need to decide on position of silencers (high or low) when the chassis is altered & seat unit fitted then i can get some downpipes bent up.
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playing with position of silencers,
standard.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01575.jpg)
the 'Matchless'
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01577.jpg)
The 'Ducati'
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01578.jpg)
i think i prefer the last one & looks best for ground clearance & i wont burn my thighs ;D
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Got a little bit more done.
Chassis rails cut down.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01579.jpg)
a bit of triming to fit the seat unit still needed around shock top mounts to get it to sit at the right angle, i decided to use the original seat base for strength & support, i will utilize some of the original foam & seat cover rather than the crap foam pad on the rs seat unit and trim the front of the rs unit to fit the seat pad.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01591.jpg)
original back light & bracket should fit nicely, cut down & re welded to frame rails, also i should be able to have the seat lock in situ. With the tabs on the front of the standard seat base it should be held secure & lift on & off like a factory seat.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01587.jpg)
Original battery tray & electrics to be mounted under seat hump with plenty of room
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01589.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01593.jpg)
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Got some time on the engine this evening,
654cc Piston (100.5mm) giving 11.24:1 compression with an xbr500 head. Rings cleaned & checked, bore is ok with honing marks still visible, i will probably re hone it anyway.
Secondary cam chain tensioner fitted on the barrel.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01621.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01622.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01634.jpg)
Started on gas flowing my head, ist removing burrs & rough casting marks, standard heads are supposed to flow quite well so just a little smoothing of the ports needed & no drastic material removal necessary.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01632.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01631.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01629.jpg)
Standard valves checked, guides checked. R&D valve springs & retainers to go in.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01633.jpg)
Will finish off when i vapor blast everything & double check with a little polish up.
Also got a blanking plate for the redundant starter gear recess
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01636.jpg)
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Looking like it's coming long nicely, it's good when you work out where bits and pieces look best, btw, I like the silencers the same way you do- keep us posted!
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cheers mark, hows yours coming along?
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cheers mark, hows yours coming along?
Sorry 'Dave' this is where the edit function would be handy ???
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I think the word is 'slow'... I keep putting bits together then taking them apart again to do something else... I think I've got mostly what I need now, it's just a case of assembly and leaving it assembled!!!
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Just about sorted the fit of the seat unit, decided to cut down the front of the seat base where i was going to use much of the original seat foam for a more minimalist seat pad, still plenty of foam under your bum so shouldnt be too uncomfortable.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01654.jpg)
Got the back light recess just about right, needs a little more shaping to sit right then i can weld the back part of the frame rails i have cut off in the right position & fit the seat lock. (The seat unit locates & lifts off nicely).
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01652.jpg)
Started prepping the seat & tank for gloss black paint.
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01637.jpg)
Kelly Brook was unavailable on the day of the photoshoot guys sorry about the stand in :o
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01648.jpg)
Jobs to do, rebuild forks,
finish head gas flowing & rebuild engine,
make hangers for silencers,
bend up some stainless headers,
zinc plate all the fastners, Done my old 16t front sprocket
(http://i310.photobucket.com/albums/kk433/golfsquad/Honda%20XBR500%20cafe%20racer/DSC01661.jpg)
powdercoat chassis,
upholster seat base & fit bum stop from original pillion cowl,
find a JMC swingarm ::)
get me some of those nice spoked rim conversions on original hubs 8) 8)
so all in all, be ready around this time next summer :P
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quick update, been really busy with no time, space & other projects have limited progress.
Anyhow been changing tack a bit with what i want the overall project to turn out like so have decided to sell the wheels, swingarm, brakes (new) hagon springs f&r, forks, yokes, bars, etc etc (see classifieds)
hopefully will have some updates soon
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had a chance to get a few bits done, cases vapour blasted.
(http://i310.photobucket.com/albums/kk433/golfsquad/pmhclassics/DSC02606.jpg)
(http://i310.photobucket.com/albums/kk433/golfsquad/pmhclassics/DSC02607.jpg)
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brief list of new parts to fit:
Aprilia RS125 09' front end with radial brakes
Aprilia 650 Pegaso hubs being rebuilt with 17" alloy rims by Steve Lomas at Five One Wheels.
Honda Cb400 super four alloy swingarm,
Yamaha XJR1200 Ohlins piggyback Shocks
Aprilia RS125 race rearsets
im hoping the final look will be 'modern' cafe racer.
I want to fit a monza cap to the tank, does anybody know where you can get a weld in threaded stub for the steel tank? or if you can get an adapter to fit in the original recess?
otherwise just needs the engine putting back together, some powdercoat & paint & stainless downpipes making up. :P
pics to follow soon.