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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Cafe ala Carte UPDATE!! Current status June 08 /cgi-bin/YaBB.pl?num=1196943498 Message started by smokin_blue on 12/06/07 at 04:18:18 |
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Title: Cafe ala Carte UPDATE!! Current status June 08 Post by smokin_blue on 12/06/07 at 04:18:18 I am happy to say project Cafe ala Carte has finally begun. I thought some of you might be interested in seeing some of the work. The goal of this bike is to build an ultra-clean and ultra-minimalistic 1960's style cafe bike using a Savage engine. The engine is a 1997 with 2,000 miles on it. The frame is from a 1968 Wards Riverside 260 Mojave (made by Benelli in Italy). This was a frame that was a knock off of a Rickman racing frame and orginally made by Benelli to house a 650 twin. It was a bike that never made it past prototype stage but they ended up using the frame for the Wards bikes. My build will be in two phases. The first that I am in now is what I am calling the Title Build. To title the bike I need to take it in as a running functioning bike so this first build is a very rough fast build to get the title work going. Once I have the title in hand I will tear it down to the ground and start over and do it right. Here is a picture of the Mojave frame. http://www.street-unique.com/CafealaCarte/Photos/FRAME.JPG As of November I had gotten the engine in the frame. I have modified a GS450 swing arm to fit it. The GS450 is the correct length and much stronger and better looking than the stock unit. The picture below shows the bike with a GT250 swing arm on it which I will use for this build since the GT rear wheel fits it with no mods. Eventually it will have either the GT or the Savage rear hub laced up to a polished aluminum high shouldered rim from a 1975 XS650. http://www.street-unique.com/CafealaCarte/Photos/CAFE-NOV2007-MED.JPG In the second build I plan to cut out the swing arm pivot plates and replace them moving the pivot (and engine) down about 1" to 1-1/2". The rear shocks are currently stock Savage units, again for the title build only. I would like to put a set of gassers on it for the final build. I have updated the post further down. Updating this one truncated it >:( |
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Title: Re: Cafe ala Carte begins! Post by Savage_Greg on 12/06/07 at 04:43:58 I like it! I like it alot! |
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Title: Re: Cafe ala Carte begins! Post by grail21 on 12/06/07 at 05:18:55 Hell yeah! I really like where this is going and I love that there are more folks doing full on custom rebuilds with the Savage. Keep up the good work man. |
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Title: Re: Cafe ala Carte begins! Post by mpescatori on 12/06/07 at 05:19:59 Wunderbar !!! And, as many people suggest what they would like on their bike, may I suggest:
:) |
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Title: Re: Cafe ala Carte begins! Post by Rogue_Cheddar on 12/06/07 at 11:16:22 Now this beats the crap outta the pap they push on "American Chopper". We want to see bikes being built, not Mikey and Pauly shooting clay pigeons or throwing paint balloons at each other. Thanks for the pics, keep em coming! |
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Title: Re: Cafe ala Carte begins! Post by srinath on 12/06/07 at 12:48:06 GS500 ... did you say GS500 ... man now you're talking my language. You dont want the heavier but much better katana 600 ?? OK fine for this things 200 lb weight and 25 hp, a bicycle fork is over built. But ... yes good choice, you're not doing exotic crap that does nothing on these low power, light, low tech, old skool stuff. Cool. Srinath. |
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Title: Re: Cafe ala Carte begins! Post by PerrydaSavage on 12/06/07 at 13:45:56 8) Great stuff!! As a previous post said, "keep it comin'" ... fabulous work! Can't wait to see the finished product! 8) |
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Title: Re: Cafe ala Carte begins! Post by Brewbrother on 12/06/07 at 14:23:47 That is a fine looking start on a cafe. looking forward to the final product. ;D |
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Title: Re: Cafe ala Carte begins! Post by smokin_blue on 12/06/07 at 19:57:24 Thanks for the comments and support! Mpescatori - - I hear you about the 4 shoe drums but at this point I can't bring my self to paying $300 plus for an old 4 shoe hub. The racers are paying top dollar for them. My plan is a bike that from 25 ft away looks like a 1960's gem but up close it is sprinkled with modern technology. The front brake (I like 1 or 2 finger stoping power ;D ) is going to be a 320mm Ducati rotor grabbed by a twin piston Tokico caliper off a 600 katana (same as on the SV650). Rogue - Personally I can't stand the Tuddly's. The only credit I will give them is a little jealousy in that they have a great marketer, they are filthy rich, and they get to play in the shop while I toil for "the man". srinath yes the GS500 fork was chosen for a number of reasons. First the GS500 weighs about the same as the savage. I needed forks from a bike that had a fairly tall engine so they would be long enough. I wanted as large as I could get but ones that could still be cleaned up to look like late '60's style, They are 37mm (not too shabby) and they fit the old large GS triple clamps. I have made several pairs of triple clamps on past projects but didn't really want to have to go there on this bike. Lastly because many of them were raced in club racing you can get full valving and spring kits for them. Now luck would make it that I snagged a set on ebay from a guy that was parting out his old race bike and just last year he had put new seals, Race Tech valves and springs in them!! $105 to my door! over $200 in valving and springs in them. As far as the katana forks go they would force me into making triple clamps to have the old style look and also they are sprung way to stiff for a bike that is targeted to come in at about 300 lbs. I really want to break sub 300 but we will see! Add a fork brace and the old GS500 forks do pretty well. Rock on guys! I will post more pics as it progresses! |
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Title: Re: Cafe ala Carte begins! Post by smokin_blue on 01/12/08 at 12:30:33 Here is an update of my work to put a new front end on the Benelli frame. I am using GS1100 triple clamps because they look correct for the era and will fit the GS500E forks (37mm). The issue is the stem is too short for the Benelli frame and I want the Savage style stem and top nut. So I had to "stretch" the stem. Here is a photo tour of the work that took place in Dec and early Jan. Here are the original parts. GS1100 triple on the left and LS650 on the right. http://www.street-unique.com/CafealaCarte/Photos/misc/GSLS_LOWERTT.JPG The I pressed the stems out. The LS came out nice the GS maxed out my 12 ton press. Some heat on the triple clamp took care of it and it went with a BANG! http://www.street-unique.com/CafealaCarte/Photos/misc/GSLSPRESSED.JPG Here are the stems side by side with the LS on top. It takes a nut where as the GS's had a bolt. http://www.street-unique.com/CafealaCarte/Photos/misc/GSLSSTEMS.JPG Suzuki made one small change in the LS by having the press diameter 0.004" lager than the bearing dia. I turned it down on the lathe to match the GS design. http://www.street-unique.com/CafealaCarte/Photos/misc/STEMMOD1.JPG The to do the stretch I was going to cut the pieces and put in a spacer. http://www.street-unique.com/CafealaCarte/Photos/misc/STEMMOD2.JPG Then face off the ends so they are square. http://www.street-unique.com/CafealaCarte/Photos/misc/STEMMOD3.JPG Then bore the ID slightly to make sure it was true and concentric with the OD. http://www.street-unique.com/CafealaCarte/Photos/misc/STEMMOD4.JPG Here is the stem cut and ready for the spacer. http://www.street-unique.com/CafealaCarte/Photos/misc/STEMMOD5.JPG |
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Title: Re: Cafe ala Carte begins! Post by smokin_blue on 01/12/08 at 12:31:33 CONTINUED... Now to start on the spacer. Select one fine piece of cold rolled steel. http://www.street-unique.com/CafealaCarte/Photos/misc/SPACER1.JPG I turned down the OD to match and then the ID to fit in with a slip fit. http://www.street-unique.com/CafealaCarte/Photos/misc/SPACER2.JPG Then cut if off and do the same to the other end. http://www.street-unique.com/CafealaCarte/Photos/misc/SPACER3.JPG Here is the new stem pieces http://www.street-unique.com/CafealaCarte/Photos/misc/NEWSTEM1.JPG Here is the stem assembled. It was then cross drilled and pinned. Once everything is final I will weld it solid. http://www.street-unique.com/CafealaCarte/Photos/misc/NEWSTEM2.JPG http://www.street-unique.com/CafealaCarte/Photos/misc/LOWERSTEM.JPG Next a little grease on it and into the press for assembly. No heat needed on this one. First the stem then the bearing. http://www.street-unique.com/CafealaCarte/Photos/misc/PRESSINGSTEM.JPG http://www.street-unique.com/CafealaCarte/Photos/misc/PRESSINGBEARING.JPG Now here is the GS1100 lower triple clamp with the newly stretched stem. http://www.street-unique.com/CafealaCarte/Photos/misc/NEWLOWER.JPG Now on to the uppers. Here are the uppers side by side. Note the small hole in the GS must be enlarged to match the LS. http://www.street-unique.com/CafealaCarte/Photos/misc/UPPERS.JPG I set it up in the mill and indicated in the hole (centered it under the cutter) and hogged it with a 3/4" cutter. http://www.street-unique.com/CafealaCarte/Photos/misc/HOGGINGUPPER.JPG Then I finished sizing it with a boring head. http://www.street-unique.com/CafealaCarte/Photos/misc/BORINGUPPER.JPG |
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Title: Re: Cafe ala Carte begins! Post by smokin_blue on 01/12/08 at 12:32:10 Here is the new triple clamp! http://www.street-unique.com/CafealaCarte/Photos/misc/NEWTRIPLE.JPG Then I pressed in the new cups and races into the frame. http://www.street-unique.com/CafealaCarte/Photos/misc/CUPSONBIKE1.JPG http://www.street-unique.com/CafealaCarte/Photos/misc/TOPCUP.JPG Here is what it looks like now with the GS500E forks set in place. http://www.street-unique.com/CafealaCarte/Photos/misc/FORKSON1.JPG http://www.street-unique.com/CafealaCarte/Photos/misc/FORKSON2.JPG http://www.street-unique.com/CafealaCarte/Photos/misc/NEWFRONTEND.JPG Soooooo.....now it is time to put some braking on this beast. I am going to use the hub that is on that rim which is a GT250 hub (same as all the spoked GS's) and lace up a high shouldered aluminum rim when it is done. But for brakes I will not be using the GT rotor but a larger 320mm Ducati 996 front rotor (thank you ebay! Brand new $50) Here is a comparison of size with the stock LS650 wheel. http://www.street-unique.com/CafealaCarte/Photos/misc/ROTORCOMPARE.JPG I will need to make a spacer to move the rotor outboard as the offset is less than I need but that will allow me to set up two bolt patterns as there is a 2mm difference in bolt cirlce diameter between the Suzuki hub and the Ducati rotor. But more on that in the future!!! Until then keep the rubber side down!! |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by rigidchop on 01/12/08 at 18:51:59 great work!!! that rotor is huge in comparison to the wheel, i like it. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/12/08 at 19:39:38 Yes I am anxious to see what kind of stopping power I will have. I am trying to get the bike down to 300 lbs. I am going with a 2 piston Tokico off of a Katana combined with that rotor and stainless brake line ought to about stand it on it's nose with 2 fingers on the lever. 8-) |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by justin_o_guy2 on 01/12/08 at 21:54:43 Yep, beats the TV shows on bike building. Good going. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by LANCER on 01/13/08 at 06:38:40 Love your work. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by Ed L. on 01/13/08 at 12:45:31 Very nice so far, real professional work you are doing. ;D ;D |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by YonuhAdisi on 01/13/08 at 13:27:08 I love your work, I want your equipment. (picture me green with envy) |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/13/08 at 13:36:35 Thanks guys! I spent my life growing up the son of a shop teacher who had a shop at home with kind of one of everything. When I moved out and into an apartment I about went nuts! Since we got our house 12 years ago I have spent my spare money picking up equipment. Most of it is old and used but that is the best kind. Usually it is built better than most of the cheap stuff today. Some of it I end up rebuilding but then it is a nice piece for a nice price! ;) |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by SavageWahine on 01/13/08 at 13:49:16 45737269745D78756F751C0 wrote:
I second that!!! It really pays to have the right tools!! |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/14/08 at 19:13:41 5C4659545B5142545D5C5B50350 wrote:
I second that!!! It really pays to have the right tools!![/quote] I totally agree with it paying to have the right tools for the job. I now have my own shop that is 1/2 wood working and 1/2 metal working. I have been able to justify the expense of the tools by the furniture we DON'T have to buy. In the last 8 years I took up cabinet making. Previous to that it was smaller items. I spent 2 years building Bad Attitude in my little bit of spare time so I was getting behind on a few other projects I had promised my wife. Last winter I knocked out two projects. This is the last one that cleared the way for me to go back to building a bikes and start on my savage cafe bike. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/14/08 at 19:16:18 Oh, and here is what I made my son for his first birthday. I made the paterns free hand at my parents cabin that summer based on memory of my Suzuki TS 250 . I knew I was getting carried away when I started routing tread on the tires. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by Savage_Greg on 01/15/08 at 04:59:57 Very talented, quality work...a craftsman. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by Trippah on 01/15/08 at 05:38:21 Beautiful work. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by LANCER on 01/15/08 at 06:50:45 Would you like to spend the rest of the winter at my place ??? plenty of projects to help keep you out of trouble ......... can't afford to pay you anything but will feed you .......... :D |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by SavageWahine on 01/16/08 at 19:50:00 Love your carpentry work! Did you make your own molding for the cabinet? |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/17/08 at 03:05:38 5F455A57585241575E5F5853360 wrote:
No I don't make much molding if I don't have to. I will when I have to but if it is a available it doesn't pay to mess around with it. I did buy the cutters a few years back to do rail and stile doors with flat or raised pannels. Those cutters have paid for themselves many times over. That cabinet one was practice for the big cabinet/ book shelf that I am going to make to go with it. That was a stereo cabinet and the book shelf will be the same basic style but have a cabinet with raised pannel doors on the bottom with open book shelf on the top. I am planning for it to be about 8 feet wide and 7ft tall. I have agreement from my wife that that unit can wait until I am done with my Savage project. 8-) |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem wo Post by SavageWahine on 01/18/08 at 18:51:20 I've been wanting to build a roll top desk for a while now, you know the kind with all those shelves and slots (maybe incorporate a hidden compartment), drawers on the bottom half. The kind they used to make. The last big project I did was make a keyboard stand and seat, out of plywood. It came out pretty good. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 01/19/08 at 19:40:25 Very nice work! |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by Savage_Greg on 01/20/08 at 07:16:00 I know how to build a good work bench, if that counts ::) Nice job. |
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Title: Re: Cafe ala Carte UPDATE!! Steering stem work Post by smokin_blue on 06/03/08 at 03:16:33 As of June 2008 - Progress has been very slow due to other responisibilities..(Man life can get in the way of fun some times!) Here are pics of the adapter ring I machined to mount my new Ducati rotor. The rotor is 320mm in diameter so it is huge. With the twin piston binder I am going to put on it should about stand the bike on its nose! http://www.street-unique.com/CafealaCarte/Photos/ROTOR-ADAPTER.JPG Here it is mounted on the wheel. http://www.street-unique.com/CafealaCarte/Photos/WHEEL-ROTOR.JPG Now here is a bike as of today. http://www.street-unique.com/CafealaCarte/Photos/CAFE-MAY2008.JPG The seat is just sitting on it but you get the flavor. I need to get bustin' on this thing so I can get it running this summer yet to get the title inspection done before winter so I can work on the real build! All in all it is coming together nicely and I think will look very sweet when finished. |
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Title: Re: Cafe ala Carte UPDATE!! Current status June 0 Post by klx650sm2002 on 06/03/08 at 05:37:33 SR project has a 320mm front and a dinky little 210mm on the back. http://i119.photobucket.com/albums/o147/klx650sm2002/SRbrakes.jpg Clive W :) |
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Title: Re: Cafe ala Carte UPDATE!! Current status June 0 Post by klx650sm2002 on 06/03/08 at 05:55:19 And KLX has 290mm front and 240mm back. http://i119.photobucket.com/albums/o147/klx650sm2002/KLX26508.jpg Clive W :) |
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Title: Re: Cafe ala Carte UPDATE!! Current status June 0 Post by rigidchop on 06/03/08 at 17:17:29 great work blue, can't wait to see the finished product. you gonna shoot any video? |
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Title: Re: Cafe ala Carte UPDATE!! Current status June 0 Post by Hard Corps on 06/03/08 at 18:15:22 This is amazing. I can't even begin to imagine taking on this kind of project. I'm always impressed with art forms at which I'm totally incompetent. Keep up the good work. This is the real deal in custom bike building. |
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