DR800 cafe racer

[Mart]

I have at last started doing a few bits of worlk on my project. Cutting excess bit of the frame and the GSX tank still some more bits to change on both. Cutting down the GSX seat pan this may not bit the last word on the seat.Having Pan European fork yokes machined to fit the DR frame [this is my plan to move the forks forward so that they don't foul the fuel tank.] There is still some work to do either on the lower yoke or the steering stops on the frame as there are two circular protrusions on the fork yoke which foul the steering stops. I haven't decided whether to attack the yoke or the stops, erring toward the the frame as the pointy bits on the end of the stops will only need the tips to be removed and the circular bits may affect the integrity of the fork forging.







I had to get tech support in to help with the picture links. I had to buy the prongy tool to remove the tapers from the headstock; it worked a treat

[manxie]

DR800 Café Racer, this sounds like an awesome project, good luck and hope to see plenty of pic`s  Good luck 

[guest2020]

Good luck with the project Mart, really interested in this one

[Moto63]

Cutting, chopping, grinding you say!!!!..........always interested. Looking forward to seeing/reading your progress reports. Best of luck.   Cheers.. Michael

[JOOLZ]

Sounds like an interesting project, I will be following this

[guest1406]

Also looking forward to this.

Best of lukc and lots of pics!

Mackenzie

[timbo]

Yes, good luck, and keep us all posted 

[themoudie]

Aye Mart,

All the best and may I offer some inspiration?

Harris_855

My regards, Bill

[Moto63]

Great set of photos Bill, really enjoyed pouring over them. The bike on them is very similar to the ikuzawa that I bought off our great leader (Graham) the other year, the frame is very similar, personally I prefer the tank on the ikuzawa. I still have,nt got round to stripping and rebuilding it yet (hopefully in 2016) then it'll be seeing some track time hopefully. I,ll keep you all posted of any developments and thanks again Bill for posting the photos. (Your clearly a lot smarter than me )......cheers.  Michael

[Moto63]

Ps. I,m sure once he see,s them it,ll give mart some real inspiration. Get that grinder out 

[Mart]

I'm not planning anything quite as radical as that Bill. More of a US interpretation of a cafe racer, and I won't be doing any track days. For one thing I am too old to ride all scrunched up; I prefer a more upright riding position.
Mart

[themoudie]

Aye Michael,

I'm not sure about the "smart" bit, just experiment and crash things a bit until I get the sequence!  A bit like driving the GIS to draw maps. 

Aye Mart,

"Too old to ride all scrunched up", Mmmm, at 6'2" I have rear sets on the SRX and can still cope with rear sets on a Duke single. But need a stretch after 150 miles!  It still feels comfortable compared to riding around lying on yer back in 'Cruiser' mode, ape hangers (those were the days) or the current fad for forward set foot pegs and clip-ons!  The latter is also the position favoured by many Italian lightweight manufacturers of the '50's to '70's and that really screws your lower back muscles and coccyx up, as I found to my cost afore fitting rear sets.   Whatever your choice, enjoy every minute of it.    Pegs below the vertical line of your hips in the saddle (take some weight on your feet) and some bars that allow a slight lean into the 'breeze', those old Meridan Triumph bars were good. 

My regards to you both, Bill

[Smithy]

I Love the idea of this project, a stonking big single cylinder special! I haven't got the skill to do something like this myself but will be following your project with interest.

[Mart]

I'm not sure that I have the skill either, but I will find out.
I sawed the end off the steering stops yesterday; Just the pointy end that was interfering with the lower yoke forging. It now works fine and there is more than enough left on the stops for them to do their job.
today I fitted one fork tube so I could check that it didn't foul the tank [79 GS550] on full lock, that seems OK. I trimmed a bit more off the seat pan, [GSX750] drilled a few holes to rearrange some of the supporting rubbers and laid the tank,seat and H&B rack losely in place, and it doesn't look to bad to me.
I want to get the bottom of the tank modified as I think it can be made to take another 4/5 Litres. If any knows of someone who can undertake that sort of work for me in the Midlands I would like their contact number please. I have a flyer for a firm in sheffield that do that sort of work but I would prefer to get it done locally if possible. also seat covering as I am not confidant that I could do that to a satisfactory standard.
I know the fork is in upside down at the moment but it makes it easier to swivel the forks from side to side if the bottom end is not resting on the ground

https://dl.dropboxusercontent.com/u/66862194/2015-12-12%2016.32.39.jpg

https://dl.dropboxusercontent.com/u/66862194/2015-12-12%2016.32.50.jpg

https://dl.dropboxusercontent.com/u/66862194/2015-12-12%2016.38.21.jpg

[guest2020]

Nice one Mart, really starting to take shape