Thumper Club Forum
Technical => Project Progress => Topic started by: guest1529 on June 30, 2012, 07:17:49 PM
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after finishing the cb750 kz for a customer we have the next project to get on with.
only stipulations we have are
1 to be road legal
2 be done to the given budget
3 to be done in 2 months completed with mot ( we still have to make the carbon parts & cafe racer seats so can only spare a couple - max hours a day at the moment)
so i can do what i really want with this little beauty.
before it came to us someone had tried to cafe it & failed miserably,
the original handlebars were put under the top yoke, had a custom stainless exhaust built
unfortunately its more like street fighter than cafe racer, & then lost the fuel tank, lucky we have a few in stock & moulds to make others
it had been left in a garage not running for a few years
started out looking like this
(http://i42.servimg.com/u/f42/17/12/80/38/photo_11.jpg)
the first thing we did was to get it running, put fresh fuel in the small tank we use, connected a charged battery, pulled the choke on & stabbed the start button & expected nothing - it proved me wrong turning over & firing up first try & ticked over smoothly till warm then ran perfectly off the choke - hope the rest of the build goes like this
next had a play with some seats & tanks we have to get the look we want (roughly)
(http://i42.servimg.com/u/f42/17/12/80/38/photo_12.jpg)
after a couple of hours today the bike was just a pile of bits
(http://i42.servimg.com/u/f42/17/12/80/38/photo_13.jpg)
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Yesterday we had a thinking day - well ten minutes thinking & a couple of tins of diet coke.
We decided on the colour of the bike.
The frame & decals down the centre of the mudguard, tank & seat is going to be candy fools gold
(http://i42.servimg.com/u/f42/17/12/80/38/fools_10.jpg)
The tank, seat & mudguard are going to be black
well black / grey
well if im going to be honest we made the seat unit yesterday & its not going to be painted at all
have you guessed what it will be yet?
(http://i42.servimg.com/u/f42/17/12/80/38/photo_14.jpg)
That was taken out of the mould an hour ago without any finishing, the edges want finishing & the whole lot wants flatting & lacquering, may even put a faint gold pearl in the top coat.
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Today we completely striped the bike down, cut off all the unwanted brackets, main stand & subframe,
then welded some small gussets in the triangulated part where the side panels went & a bar where the subframe was cut back (to mount the light & number plate bracket)
(http://i42.servimg.com/u/f42/17/12/80/38/photo_16.jpg)
the frame & swinging arm are off to the sand blasters on monday should have any imperfections on the standard welds filled & acid etch primed & 2 pack high build primed by wednesday/thursday.
Then a quick dry build with tank & seat before full paint on frame & swinging arm - that will take a few days as it has a silver base coat (3-4 coats), then the candy (up to 6 coats) & finally the top clear coat (4 coats).
In between the painting the frame i will be stripping & cleaning the engine (externals only as it ran perfectly) painting matt black & doing a bit of polishing
(http://i42.servimg.com/u/f42/17/12/80/38/photo_17.jpg)
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....................... so can only spare a couple - max hours a day at the moment)
Its amazing what you can do when you "can only spare a few hours a day" :o ??? ::)
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I wonder if Graham is drooling yet?
Trevor
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Have fun It looks like a great project. What tank is that in the photo
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Have fun It looks like a great project. What tank is that in the photo
it started life as a bsa tank but has had a few teaks to make it look a bit more "cafe" if you know what im saying, we have the mould for the top of the tank & just make bottoms to suit the bike
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The frame & swinging arm have returned from the blasters, they are using a new medium which doesnt do any harm to bearing surfaces or threaded areas, & it makes a fantastic job (did cost a bit though)(http://i42.servimg.com/u/f42/17/12/80/38/img_0510.jpg)
(http://i42.servimg.com/u/f42/17/12/80/38/img_0511.jpg)
Spent a while filling & smoothing the welds that are seen & will get it in acid etch & high build primer tomorrow, maybe in silver base coat if i get time.
Over the couple of days that the frame was away i have cleaned & de-greased the engine giving the rocker cover a quickish polish with the wire brush on the drill, the covers have been sent to the polisher & all the little brackets have been painted. will post pics of engine when i get the covers back & rebuilt.
Ordered a massive lot of stainless nuts bolts washers & allen bolts for it - should do every nut bolt on bike with these.
I found a pair of rs250 spokies on ebay quite cheep, got the front fitted in the xbr forks today & it fits & lines up perfectly, just need to sort a disc out, will have a look at the rear next week (http://i42.servimg.com/u/f42/17/12/80/38/img_0512.jpg)
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That RS250 rim looks good in there, you might want to whip the tyres off and check them out though as they have a habit of delaminating inside.
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cheers mate
i will be checking the wheels & making any repairs needed & fitting new tyres.
Got the frame acid etched primed & high build primed, not happy with a few imperfections in the finish so a bit more filling & flatting required before getting the base coat on.
(http://i42.servimg.com/u/f42/17/12/80/38/photo_18.jpg)
(http://i42.servimg.com/u/f42/17/12/80/38/photo_19.jpg)
Had another play with the front end with the spoked wheel & looked up & measured various discs to suit the rs wheel, found an old cb900f disc we had kicking around & it fitted & lined up perfectly, might have to machine 2mm of the caliper mounting bracket
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Not had much time to get a lot done this week as we have been very busy selling & making loads of cafe racer seats & having meetings with the web designer - new website coming soon just for cafe racer parts.
excuses over, I will be working all day sunday on this.
We have had a few new parts delivered, stainless bolts, k n style air filter & exhaust.(http://i42.servimg.com/u/f42/17/12/80/38/img_0513.jpg)
finished flatting, filling & re priming the frame spent 4 hours doing that!!
then managed to get the frame, swinging arm, side stand & torque arm in bright base coat silver, tomorrow the frame & swinging arm will get the candy applied & finished in top coat.
the engine has been stripped of its covers( which are at the polishers) the whole lot has been de greased & wire brushed, the rocker cover has been cleaned & lightly polished. the rest inc crank cases have been painted in gloss black engine enamel. all the bolts nuts etc have been replaced with stainless allen bolts
(http://i42.servimg.com/u/f42/17/12/80/38/img_0514.jpg)(http://i42.servimg.com/u/f42/17/12/80/38/img_0515.jpg)
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got the frame & swinging arm in the candy colour today & 1 coat of clear on
(ran out of lacquer so the other 2 coats will go on in the morning)(http://i42.servimg.com/u/f42/17/12/80/38/photo_20.jpg)
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today the owner came in to pay his parts bill, or thats what i thought he was going to do
instead we had the kleenex speech that goes like -
" i cant afford to do this bike anymore (even though we are well under budget so far)
lost my job girlfriend pregnant, car failed mot, etc, etc" :'( :'( :'( :'(
passed him the tissue - metaphorically speaking & told him he couldnt take the bike until he had paid the parts & labour so far.
another project never to be finished.
so instead of letting you lot down i agreed to give him a small amount of cash (well i am a yorkshire man)& let him off with what he owed us
15 mins later he came back with the log book.RESULT ;D
Now the pressure is off to meet the deadline shall i
1 still do it in 2 months or relax with it
2 sod the budget & go all out on it
3 brake it for parts & make some ££
or 4 carry on as if nothing has changed.
SOD it - off to see the guy that does my chrome with loads of bits then ordered every other nut & bolt i dont already have in stainless,
ITS MINE NOW SO THE BUDGET WILL STRETCH SLIGHTLY but still keeping the deadline
rant now over
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Getting exciting this Innit! :D
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Yesterday i managed to get the bottom yoke, torque arm & side stand in base coat,
colour & lacquer, its starting to come together now.
(http://i42.servimg.com/u/f42/17/12/80/38/photo_21.jpg)
Today started off very well with some bits returning from the polisher
(http://i42.servimg.com/u/f42/17/12/80/38/photo_22.jpg)
so after the working day had finished i decided to spend a couple of hours building the engine up, putting the polished cases on & changing every bolt for a stainless allen bolt.
All looked good
(http://i42.servimg.com/u/f42/17/12/80/38/photo_23.jpg)
(http://i42.servimg.com/u/f42/17/12/80/38/photo_24.jpg)
Then just as i was tightening the genny cover down it all went pear shaped
IN A BIG WAY
(http://i42.servimg.com/u/f42/17/12/80/38/photo_25.jpg)
I used an allen bolt & washer on the genny wire retaining clip bolt, which must have been touching the crank case, i wouldnt mind but i was hardly tightening it not swinging on it like a bloody monkey!
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Bugger, bugger, bugger !..................... :'( :'( :'(
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got a new case for it instead of having it welded, the crack ran down most of the inside of the case.
its arrived & gone straight to the polisher, should be back next tues / wed
the chrome engine mounts should be with me by monday so should get the engine in by tuesday
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Didnt get much done last week as we were very busy with the cafe racer seats we sell, brought 3 new types out & selling loads.
Had another look at the carbon seat we made for this bike & it looks too wide at the back & a bit bulky too, so i got my lad who is an ace plug maker(does all ours) to make a seat plug especially for this bike he only had 1 day as he was needed to make seats that have been sold.
whilst he was doing that i prepped the tank for painting ready to make the moulds.
This is what we ended up with after a bit of black 2k paint. mould making started today.(http://i42.servimg.com/u/f42/17/12/80/38/photo_26.jpg)
I tried to get new swinging arm & wheel spindles from honda as these were a bit grotty,but they are no longer available so had a word with my chromer who plated the nut ends, not only that but he also plated the end that pokes through the nut just before the thread (i never asked him to - but thats one of the reason i use him)
The chrome engine mounts came back on saturday so we skipped lunch today to have a little play, just waiting for some more bits coming back from the polisher & the moulds to be finished tomorrow then we can make the carbon bodywork
(http://i42.servimg.com/u/f42/17/12/80/38/photo_27.jpg)
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wow fantastic work cant wait to see this finished tommy
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Looking very good :)
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Love those rear shocks..... i've changed my mind about the price- you owe me a few quid!!!!
Looking good!!!!
John
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yep look really good on the bike
another bargain from john, he is breaking a xbr500
he is very fair on his prices, delivers quickly & gives accurate descriptions
hes helped me out with a few bits-cheers john
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Hi, thanks for posting detials of this progest, a fine peice of work. Re the rs wheels, I just fitted an rs frony to my bike but found I needes to fit a spacer on the speedo drive side to line the wheel up correctly. Did your wheel line up ok without a spacer? I think the profile of the rear is a bit narrow, do you know of an alternative? Thanks again for the info in this progect report. Do you intend to sell the seat humps and if so - how much?
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Hi, I forgot to mention that the rs rear has a 47T sprocket fitted and I'm having no luck in finding a 34T - any advice on this one? Thanks.
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Hi, thanks for posting detials of this progest, a fine peice of work. Re the rs wheels, I just fitted an rs frony to my bike but found I needes to fit a spacer on the speedo drive side to line the wheel up correctly. Did your wheel line up ok without a spacer? I think the profile of the rear is a bit narrow, do you know of an alternative? Thanks again for the info in this progect report. Do you intend to sell the seat humps and if so - how much?
to be honest i only checked basic fitment of wheels they could need a spacer, but i wont know until they come back from the wheel builders, yes the back may be going witha larger than standard rs rim if we can get matching ones to the front, will keep you updated
as to the seats we sell these in 3 options
1 straight from the mould - £59.95 inc uk delivery
2 painted in 2k gloss £89.95 inc del
or 3 carbon fibre £159.95 inc del
this is the one for this bike in carbon
(http://i32.servimg.com/u/f32/17/12/80/38/sany5110.jpg)
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(http://i32.servimg.com/u/f32/17/12/80/38/photo110.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo210.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo310.jpg)
latest pics excuse the wheels the spokies are being rebuilt
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Hi, I have just fitted an rs 250 front wheel (CB750 disk ordered as advised) but I had to use a 5mm? spacer on the speedo drive side to get it lined up so you might need to check this on your project bike. Re the rear wheel, I'm having trouble finding a 34T sprocket to fit this hub - have you any ideas on this? Your finished project is gona be one class looking bike.
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B&C Express are local to me and will make you almost any size/pitch rear sprocket you want as a one off. They are not cheap, but not over expensive either for a one off item. They may also be able to advise on an alternative sprocket - I seem to remember that the Honda CB350S uses the same hole spacing as the XBR but with different amounts of teeth.
www.bandcexpress.co.uk (http://www.bandcexpress.co.uk)
You could also ask at www.wemoto.co.uk they are really helpful.
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Hi, I have just fitted an rs 250 front wheel (CB750 disk ordered as advised) but I had to use a 5mm? spacer on the speedo drive side to get it lined up so you might need to check this on your project bike. Re the rear wheel, I'm having trouble finding a 34T sprocket to fit this hub - have you any ideas on this? Your finished project is gona be one class looking bike.
im going to get a sprocket made as it needs to be rs250 mount 34t & roughly 8mm off the offset
cheers for the comment on the project.
spoked wheels have now gone to be rebuilt trying to get a slightly wider rear rim in the same shape as the standard did poss 2.15 instead of the 1.85
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B&C Express are local to me and will make you almost any size/pitch rear sprocket you want as a one off. They are not cheap, but not over expensive either for a one off item. They may also be able to advise on an alternative sprocket - I seem to remember that the Honda CB350S uses the same hole spacing as the XBR but with different amounts of teeth.
www.bandcexpress.co.uk (http://www.bandcexpress.co.uk)
You could also ask at www.wemoto.co.uk they are really helpful.
nice one mate i will see if b&c can do an offset sprocket
we need rs250 mount with the 34 teeth from xbr
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the new engine casing is back from the polishers & on the bike.
the bike is back on its old wheels while the new spoked ones are being rebuilt, had to put it on the wheels so we could get the right level for the tank to fit.
not got that much done actually on the bike this week as we have been busy making some moulds,
for it these are now ready to make a few carbon bits for this bike they include seat )see picture of it now made), tank,chain guard, headlight bowl & fuse box cover
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Hi, steve mentioned that a cb350 rear sprocket might fit but the mount holes are 5mm out (105mm). I have sourced a cb400 (1979 - 1983) sprocket that has the correct 110mm between the mount holes, 70mm centre and 34T. When the wheel is centered in the swingarm, I have the same 8mm problem with chain alinement. Rather than have a one off sprocked made, (I'm not happy with the possible torc affect resulting from an offset drive sprocket). Also, for ease of future replacement I have had the sprocket flange milled back 8mm. This resulted in several mil off the cush drive carriers and a spacer under the retention circlip. Problem is that I had to strip the wheel for the engineet to mount the hub for milling. If you choose to go down this route you would need to have this work done before the wheel is rebuilt!!!!. Because I now have to rebuild the wheel I am fitting a 2.5 rim also. I made a detailed drawing and took several photos before striping and I'm gona have a go at rebuilding the wheel my-self -can't be that difficult - right!!!
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Hi, steve mentioned that a cb350 rear sprocket might fit but the mount holes are 5mm out (105mm). I have sourced a cb400 (1979 - 1983) sprocket that has the correct 110mm between the mount holes, 70mm centre and 34T. When the wheel is centered in the swingarm, I have the same 8mm problem with chain alinement. Rather than have a one off sprocked made, (I'm not happy with the possible torc affect resulting from an offset drive sprocket). Also, for ease of future replacement I have had the sprocket flange milled back 8mm. This resulted in several mil off the cush drive carriers and a spacer under the retention circlip. Problem is that I had to strip the wheel for the engineet to mount the hub for milling. If you choose to go down this route you would need to have this work done before the wheel is rebuilt!!!!. Because I now have to rebuild the wheel I am fitting a 2.5 rim also. I made a detailed drawing and took several photos before striping and I'm gona have a go at rebuilding the wheel my-self -can't be that difficult - right!!!
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One advantage of spoked wheels is that you can dish them to get the sprocket where you want it while keeping the tyre in the centreline.
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As far as I know it's risky to dish a spooked wheel beyond 6mm?
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WHAT DO YOU GET THIS TIME OF YEAR WHEN EVERYONE GOES ON HOLIDAY?
SOD ALL DONE ON THIS BLOODY PROJECT!!!
The polisher has some parts & more importantly the rims he is away till tuesday,The guy that builds my wheels goes away tomorrow so cannot get my wheels done for at least another week & the chromer has gone away for a week whilst he still has a few bits from the bike that i need.
The 2 months is up next week & due to these spiteful people taking holidays just to slow this project down, i wont make it. but it doesnt matter s its my bike now not the customers.
had a few disasters this week
1 put the rs rear hub in the parts washer to get all the solid grease off & a great chunk of e metal fell out around one of the bearing mounts & noticed one of the cush rubber mounts had been glued back on - into the scrap ally bin
2 couldnt find another rs rear hub or wheel anywhere so ended up buying a cb350f cb400f wheel from the early 80's
3 that cost me another £60
4 the front disc i had was warped (cost me another £22 for 2 mint ones delivered)
5 lost the charger for my digi camera so can not post any pictures this week
on the plus side some things have gone well
1 the new wheel does not need any machining, offsett is perfect just need to make some spacers
2 found a small company that will make me a sprocket for the cb wheel in xbr pitch within 7-10 days for a good price
3 got the front hub spaced up & painted it in the same colour as the frame
4 bought new braided oil lines, my lad uses a place who is very good on price & fastens them to the original connector- looks clean & new but standard
5 finished tank, front mudguard rear & mudguard moulds & made a carbon chain guard
6 polished oil tank & breather fitted back in the frame
we are getting there slowly,
7 also shaved 2mm of the caliper carrier so everything is aligned & working on the front.
we are getting there slowly,
will either get a new charger or new camera next week & post some pics
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Your last post reminds me that bike projects are much like life in general - some good times, some not so good, but you just gota role with it. Glad to hear you got the wheels sorted. Any thoughts on what tyres your going to fit?
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Will you be selling front mudguards from your mould and if so, How much ?
Excellent project btw.
Been watching with great interest.
Richard.
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Your last post reminds me that bike projects are much like life in general - some good times, some not so good, but you just gota role with it. Glad to hear you got the wheels sorted. Any thoughts on what tyres your going to fit?
[/quote
yep so true & usually when 1 thing goes wrong 3 or 4 other things tend to go wrong too!!
it came with a good pair of metzler tyres so they will be going back on
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Will you be selling front mudguards from your mould and if so, How much ?
Excellent project btw.
Been watching with great interest.
Richard.
we are using a blade type front mudguard on this project, yes we will be selling them in carbon for £59.95, we have the standard fork brace/mudguard mound chromed & have fitted the smaller blade mudguard on it -looks very retro & cool (i think)
we are also going to be making the standard xbr mudguard in carbon for £94
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sorry for the lack of posts, i have not been skiving just very busy.I am in the process of getting 2 websites sorted one for the ducati carbon & the other for the cafe racer parts, lots of photo taking & adding items to the data bases.
i decided that as everyone else was on holiday & i couldnt get my parts so i wouldnt get much done on the bike & business was quiet i might as well join them. So i had a few days off too :D
back to work now & still waiting for bits to turn up, so i thought i would tackle the wiring, which was a right mess loads of twisted wires in insulating tape, have removed the indicator wires & relays relocated all the components under the seat hump & just about sorted it. All soldered with heat shrink over the joints -took bloody hours.
(http://i32.servimg.com/u/f32/17/12/80/38/img_0510.jpg)
The body work is coming along nicely, the tank cover came out of the mould today, the seat unit, mudguards(front & rear), & chain guard are all made just need paint & lacquer.Tomorrow i am making the wheel spacers at my mates machine shop & hopefully collecting the spoked front wheel along with the front mudguard brace from the chromer, early next week we should have the front end all together & on the bike.
(http://i32.servimg.com/u/f32/17/12/80/38/img_0512.jpg)(http://i32.servimg.com/u/f32/17/12/80/38/img_0514.jpg)
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Its looking great, keep up the good work
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I worked it out today that 6 solid days would have it finished & mot'd if i concentrated on it.
unfortunately i have bits to make for customers, 2 websites to finish building (1 for cafe racer seats & 1 for carbon fibre) & new products to bring out, so probably another 2-3 weeks should see it finished & a few late nights.
Front end just about done now, still fighting with the bloody wiring though,
just got to shorten the front mudguard by a couple of inches at the front then lacquer it.
back wheel back tomorrow & sprocket & brake back plate back from polishers on friday.
might have a saturday morning on it to make a roller,
(thats all it will ever be until the wiring is done, not my favorite job)as its getting very exciting now its coming together
(http://i32.servimg.com/u/f32/17/12/80/38/photo_13.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo_14.jpg)
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The good news is
we have it on its own SPOKED WHEEL as a rolling bike
the bad news is i still havent done the wiring (still filling me with dread!!
this week we have it built up as a fully rolling bike,all spacers are correctly sized, both mudguards have been lacquered as has the chain guard, the inner tank has started to be fabricated & i have even started to make the rearset plates (no pics yet as they still look a bit rough.My lad finished all this weeks jobs this morning so didnt have anything on for today, we have been trying to work out what to do with the exhaust as its a bit grotty even though it was a purpose made stainless system(probably about 10 years ago!we had a quote for the 2 downpipes from a so called mate (he is when he wants carbon bits making he is not when i want an exhaust making) the robbing git wanted £200 for the downpipes alone. anyway my lad decided to have a go at cleaning & polishing them up even if we ended up matt blacking them.See the picture below for what he did, managed to do both in an hour or so.
Im away at a trade show for 3 days next week but project bike days are
Monday is put aside for doing the electrics & my lad is getting on with mounting the rear light in the seat,fitting the aero cap in the tank & flatting the tank. & seat for lacquer.
Tuesday making the exhaust link pipe to the mega exhaust & finishing the rearset mounting plates
(http://i32.servimg.com/u/f32/17/12/80/38/photo_15.jpg)(http://i32.servimg.com/u/f32/17/12/80/38/photo_16.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo_17.jpg)
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Had a short week this week as ive been to the bike show in Germany, but still managed to get both mudguards lacquered & now fitted, fabricated a stainless collector box & my lad polished it up & got it all fitted up with the new mega on.Had some new braided oil pipes made up to the tank & fitted them along with new o rings.Not a bad 3 hours work!
Started to cut the backing plates out for the rear sets, they should be done & fitted next week
Then i WILL do the electrics
(http://i32.servimg.com/u/f32/17/12/80/38/exhaus10.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/ehaust10.jpg)
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I am loving this thread. Keep up the good work!!!!
The exhaust is nicely done. Tucked in and no doubt LAF ;)
Rob
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I have been a brave lad this week very brave indeed :-[ ::)
FINALLY
I have spent most of the last 2 days sorting the electrics probably 8 hours in total.Removing all the wiring not needed like indicator, rear & brake light warning system, side stand switch & clutch switch. Also removed all those dodgy taped & crimped Honda joints replacing them with proper soldered joints covered in heat shrink & extended the cdi, starter solenoid & rectifier wires so they fit in the seat hump, the rectifier sits under the carbon undertray, see pic 2.to keep nice & cool, everything works as it should, turns over on the button & i even get a spark. Did have a panic moment when i couldnt get the clock lights (illumination not warning) so ran a positive & negative straight to the wires & still nothing put test light across the feeds & we had light, nothing i had done wrong just 4 blown bulbs in both of the clocks.
Fitted the new gold o ring chain & carbon chain guard & made the carbon number plate & rear light bracket today, unfortunately i dropped the led rear light & it now does all sorts of strange things, 3 bulbs on all the time only half the bulbs come on for the brake light, some leds brighter than others, must have cracked the pcb (ordered another one today along with a new battery)
Tomorrow i will fit the choke & throttle cables & fire her up for the first time since rebuild.
The only jobs left to do are lacquer the tank & seat & do the graphics on them, chequers down the center of both in the same colour as the rest of the bike, make the mounting brackets to fasten the seat unit to the undertray which is secured to the frame, make & fit the starter to battery / solenoid lead, wire the new rear light & fit the number plate then its done just in time for winter!!
(http://i32.servimg.com/u/f32/17/12/80/38/photo_18.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo_19.jpg)
(http://i32.servimg.com/u/f32/17/12/80/38/photo_20.jpg)
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I love the rear mudguard. Is it efficient enough ?
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I love the rear mudguard. Is it efficient enough ?
not sure mate, the idea is it should keep most of the crap off the cone filter,
if the engine starts to get covered in road dirt i will make a wider rear mudguard.
only time will tell
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NO im not dead ;D
Im back now,
i went on holiday for a couple of weeks, came back got whooping cough felt ******* for 4 weeks & then spent the first week back at work catching up with the things that didnt get done whilst i wasnt up to much.
Anyway last week i had just about caught up so i did a bit on the xbr, here is what i managed to get done.
Both side rear sets were roughly cut out of plate ally & fitted with the carbon heel guards,
& i got the first coat of lacquer on the tank & seat unit, just need to flat it back & do the artwork silver base coat & the same fools gold as the frame,down the center of both, possibly on wed or thurs this week - then lots more lacquer over the lot
THIS PROJECT HAS TAKEN TOO LONG & WILL BE FINISHED BY THE END OF THIS YEAR (honest :o )
(http://i42.servimg.com/u/f42/17/12/80/38/img_0710.jpg)(http://i42.servimg.com/u/f42/17/12/80/38/img_0711.jpg)
(http://i42.servimg.com/u/f42/17/12/80/38/img_0712.jpg)
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Im trying hard to finish the xbr soon so i did some more work today on the project.
My favorite job of all painting with a bit of masking too (about an hour in total masking the tank & seat).
Before masking i flatted the body work back with 240 grit on the da & lacquered the carbon to fill in the imperfections in the resin,(which you always get in the form of tiny pin holes) repeat this a couple of times, this gives a nice perfect surface, flatted the 8 or so coats of clear back using various grades of wet & dry down to 800.
First pic are both units masked & ready to apply the silver base coat
Then the base coat applied
& lastly in fools gold.
tomorrow i will be removing the masking which will take hours, lightly flatting the new paint back to remove the ridges & then clear coat over the lot, probably 10 -15 coats so the checkers are laying flat & there is a depth to the finish(http://i42.servimg.com/u/f42/17/12/80/38/photo_28.jpg)
(http://i42.servimg.com/u/f42/17/12/80/38/photo_29.jpg)(http://i42.servimg.com/u/f42/17/12/80/38/photo_30.jpg)(http://i42.servimg.com/u/f42/17/12/80/38/photo_31.jpg)
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Well i couldnt wait to get into work this morning to rip all the masking off, took me around 2 hours to unmask & then remove all the glue that the paint mask left behind.
I just had to try them on the bike! :D :D :D :D :D :D i always get this excited when doing paint work.
(http://i16.servimg.com/u/f16/17/12/80/38/img_0710.jpg)
A quick flat with 800 wet & dry a good wipe with panel wipe, a rub over with the tack cloth & back in the booth for quite a few (read lots) of coats of 2 pack lacquer,I used 700ml on these 2 parts (can paint 1/2 a car with that)
(http://i16.servimg.com/u/f16/17/12/80/38/img_0711.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/img_0712.jpg)
In between the numerous coats of clear i decided the front disc looked bland so i decided to drill it in a similar pattern to the standard xbr disc - get this fitted tomorrow after counter sinking it
(http://i16.servimg.com/u/f16/17/12/80/38/img_0713.jpg)
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Can I just say.....WOW :) 8)
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You really have got gold in your hand.
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Many thanks for the comments
really appreciate them.
just the foot pegs & hangers to finish off then its done.Seat pad should be ready on monday.
Will get it mot'd come the better weather (around april)ready for the shows.
We will be building 3 x gs550's (i know they are not thumpers but its what customers want building, if anyone wants me to i can do another thread on here)as soon as we get back in the new year & these should be finished by april (yes all 3 of them)
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Will you be doing any more seat units in carbon? Think I prefer that look to the more regular fibreglass/plastic jobbies.
As far as the 550's go then I'd be interested in a thread of the build(s). If you need any technical advise you could do worse than popping in to the Katana Owners Club site and asking as we've plenty of experience with the 550's over there (not trying to step on toes just trying to give good advise guys...).
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Will you be doing any more seat units in carbon? Think I prefer that look to the more regular fibreglass/plastic jobbies.
As far as the 550's go then I'd be interested in a thread of the build(s). If you need any technical advise you could do worse than popping in to the Katana Owners Club site and asking as we've plenty of experience with the 550's over there (not trying to step on toes just trying to give good advise guys...).
hi mate
yes we always make the seats & tanks in carbon, usually to order which takes 4-6 weeks.
I will pop over to the katana site, may even join it as no matter what you know there is always something you dont, & im not afraid to ask
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Wonderful work, looks great
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I wait with impatience each day to see how your work runs.
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Long 2 Months. Could work out to be 12 months
Maybe 2013 is going to be a good year.
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Long 2 Months. Could work out to be 12 months
Maybe 2013 is going to be a good year.
yep it was a long 2 months but as the customer signed it over to me due to lack of funds it didnt really matter, it was finished between xmas & new year.
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Had a nightmare with computers & internet since christmas, had some access at work but mainly working from the iphone, all now sorted.
THE BIKE IS FINISHED AT LAST :D
Im very happy with the result except the rear sets which i hate the look of.
had it running it started up 2nd stab of the starter button- sh1t its LOUD,TOO LOUD
Will have to baffle it before i ride it or i will loose what bit of hearing i have left.
It did start to leak a bit of oil but a quick nip round the allen bolts for the clutch case & it was sorted.
The rear sets are now off & awaiting a bit of modification with my new milling machine, mill out a recess & paint it the fools gold colour & polish the rest.The seat pad will be here on thursday then
its going under a cover till march when i will mot it & have a bit of fair weather fun on it.
(http://i16.servimg.com/u/f16/17/12/80/38/xbr_111.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/xbr210.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/xbr410.jpg)
Just started a new project gs550 i will start a new thread- will be making a full conversion kit for the gs550 / gs750
(http://i16.servimg.com/u/f16/17/12/80/38/gs55010.jpg)
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FINISHED IT OFF TODAY
then took her for a quick blat up & down the yard (1/2 mile long each way)
it is actually quite comfortable but far too loud, must put in a baffle & sort the jetting
for the exhaust & filter
(http://i16.servimg.com/u/f16/17/12/80/38/sany5413.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/sany5510.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/sany5412.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/sany5411.jpg)
(http://i16.servimg.com/u/f16/17/12/80/38/sany5414.jpg)
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Think I said this before...WOW, stunning.
Top job sir.
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Absolutely beautiful, great work
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wonderfull !!
I'd like to see what you could do with a SRX ...
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Very nice :) :)
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Excellent Work.
You might want to try some "Back to Black" on the h/bar switch boxes tho. It brings them up nice.
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P.s.
Will you be showing prog on GS550 on this forum . . ?
My next door neighbor will be interested.
Some might have you take three plug leads off tho!
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Excellent Work.
You might want to try some "Back to Black" on the h/bar switch boxes tho. It brings them up nice.
thanks
i will give that a try, ive tried to get some new old stock ones but not having much luck
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P.s.
Will you be showing prog on GS550 on this forum . . ?
My next door neighbor will be interested.
Some might have you take three plug leads off tho!
i wasnt going to as its not exactly a thumper,
but if no one minds (im sure i can get it to run just on one pot)
i will start a new thread (if its not suitable the mods can delete it :()
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here is a little video of the bike started up
you will understand why i need to quieten it down
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NO! :o Knock it off around built up areas and just go canny. Lusty single on the open road! ;D
Nae bother at all. :)
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Got loads done on this & the other 2 bikes im building.
This one will be known as gs550 7k miles
The other gs550 will be known as gs550 #2
& a gs1000 g shaftie i hate shaft drive
Will make new threads for each bike
if the moderators dont think these are suitable for this forum as they are not thumpers
please feel free to delete
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Hi to all Thumper enthusiasts.
Very impressive build Carbon Moto. Especially like your choice of paint.
I'm looking to do a similar build and am asking for a bit of info on a few specifics that I'm not sure about. I have a xbr500 I. Great shape for starting platform. Unmolested except for paint and original 38000kms. Complete save the tool kit.
Been following your build and researching and a common thread is to fit xl600 jug.
I'm in Australia and parts are rare. To give e eryone a run down on what I'm planning and any helpful tips would be appreciated.
Fit xl600 jug with .5 over weisco kit. Can I use the xbr head? Will be getting cam ground to hrc spec or similar and hard face rockers.
I have a xl600 jug, head, cover on stand by. Concerned about cam decompression.
It has a bit of top end rattle so I'll give it a birthday and in two minds about just overesizing standard bore/head with all the other goodies or using xl600 top end.
Will fit keihin fcr carb 40mm and upgrade exhaust to similar to yours.
The European models were a bit different in places. OZ models didn't have kick start and small cosmetic stuff. Does the rightcase cover off an xr/xl500/600 fit the xbr case. Wanting to have that function in case of starter failure.(common fault). May even take the starter off yet.
May even fit a 6speed box from the cbx250rs but that's later. Gearing options might be best sorted on the outside.
Brakes standard but may fit front caliper/master, with a bit of work, from later bike. Hints?
Last thing. What cams from what models xl/xr fit the xbr head? Wanting to send a spare one off for machining and keep original?
And do you ship your carbon products down to OZ? Having trouble find a suitable tank that looks as good as yours for that rear seating position. Carbon really looks better that I thought. But you did put a lot of time and layers there. A really good mix of new tech. on an old bike. Most dealers over hear turn their noses up at the mention of the xbr and solid info is like getting blood from a stone.
Will be down loading manual for the bike when my pc is fixed. Doing this from a phone.
My finger is sore...
Cheers n beers
Stu
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If you're using a 600 barrel it might be wise to use the 600 head. The starter is under enough strain already without the added compression.
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Thanks gb500nz.
What's your reasoning other than high compression?
4strokes love high compression. Is there any issue with parts fitting? Decompression cam???
I think I'm going to start my own thread for info on this build as I'm a mechanic but I work mostly on mining machinery that's not really in the groove of cafe style bikes. and as this is my first build for big single. Plus I think that i don't want to be responsible for corrupting a really nice thread of a build with my novice questions of the bike in question.
All those who have read. Please look out for the Aussie xbr build. It will be slow and methodical. I don't like doing things twice. Hopefully by next summer in the southern hemisphere I'll be spending my weekends making my triumph mates look like the corners are made of blue tack.
Cheers
Stu
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Oh and anyone has some spoked rims to send down under at a reasonable price I'd be in your debt.
Here's a URL that might interest some gb riders. If you can get through the bad English text there's some interesting stuff.
Thanks
Stu
GB400TT TUNE - amy．hi-ho．ne．
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Hi to all Thumper enthusiasts.
Very impressive build Carbon Moto. Especially like your choice of paint.
Cheers Stu
yes we can ship to the "land down under" & often do
We made this tank & seat especially for this build (it does fit other bikes) & is now a good seller in carbon & fibreglass, we also sell the exhausts, rear lights, headlight brackets & clipons which are fully adjustable.
Dont go for the gb500 spoked wheels as they cost a fortune, i used a cb250 rs front wheel with a cb750/900 disc skimed 2mm off the caliper bracket. the rear is a cb360 laced to the rs rear rim, it had to be laced 6mm over to the brake side to get the wheel central -Then we machined up the spacers to suit
If you need any advice on your build just ask me, or anyone else on here
tony
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Thanks Tony
Does the cb250rs rear hub fit. Bummer if it does. My friend just sold two of them.
Wondering if any other hub suits. Xl,xr. Much easier to find in OZ.
Read a blog from a Japanese gb400 rider. Said he fitted 3' rim to the rear. Had only 1.5mm clearance with avons but it didn't rub at high speed. Are they the same swingarm? Thinking I'll attemp the same if I can source a good set of hubs/rims to suit the centre, and dress it up with some stainless spokes and some shiny black alloys.
That's pretty much my last question for now. Will be starting a thread soon.
Stu
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I fitted an XL600 barrel and piston to my XBR and kept the original 500 head.I used two base gaskets to try to lower the compression slightly.(with hindsight I would have used three).The starter will not turn the engine fast enough to fire when cold,but it will just-only just-fire it when hot.I use the kickstart normally.Without the decompressor,kickstarting would be impossible.The wide swing of the kickstart and the force needed to kick it will tilt the bike sideways.
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Does the cb250rs rear hub fit.
The cush drive in the 250RS is very poor. The later electric start 250RS hub would be a better choice
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If you're using a 600 barrel it might be wise to use the 600 head. The starter is under enough strain already without the added compression.
I get what you mean now after the quote from "Blew" about tipping the bike.
Luckily the barrel I sourced is still in a bike at the wreckers and he has quoted a fair price for the head. I'm assuming the xbr rocker box/ head cover fits but some advice here would be good before I pull it all down. Might take the whole engine for spares if the price is right.
The OZ models didn't come with kick start and I've sourced but not paid yet, for shaft and gearing, right case and kick bar for a a reasonable price. Hoping the shaft will slip on toe this model...
Apart from rims, a piston kit and gaskets I'm just about ready to start. But they can wait. Want to sort out the kinks in the engine first. Oh and a bit more cash would be nice. He he
Kind of reluctant though. It really is a good example of the bike as standard and runs sweet and clean. But I know I'll want more.
Any advice on pipes and carbie set up. Can the original carb be jetted well enough to suit the bigger bore and starting to wonder about oil flow to the top end being to slim. Had that problem with a klr650 after doing some work up top.
Thanks guys for yr help.
Stu
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Just been browsing in some of the old threads and come across this one. Did anyone see the finished project.
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you are more than welcome to come & see it its sat in our unit waiting to get mot'd again for this year,
we have done a few tweaks like changed the exhaust ect
tony
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Just read the complete thread, a fantastic piece of work. Only comment I can make, is WOW! :D
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you are more than welcome to come & see it its sat in our unit waiting to get mot'd again for this year,
we have done a few tweaks like changed the exhaust ect
tony
If you were a bit nearer I would be round to ogle and salivate. Excellent job and credit where credit is due. Cheers.
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after putting this bike into storage with minimal use we decided it had to come out & be used in anger this year.
we changed the exhaust for our best selling gp version & took it for the mot
which it sailed through with no advisaries see our facebook page for finished pictures
https://www.facebook.com/CompleteCafeRacer/photos/pcb.1609218649318098/1609218509318112/?type=1&theater (https://www.facebook.com/CompleteCafeRacer/photos/pcb.1609218649318098/1609218509318112/?type=1&theater)
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Lovely lovely lovely :)