|
SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Cafe Racer Project /cgi-bin/YaBB.pl?num=1411790973 Message started by paulmarshall on 09/26/14 at 21:09:33 |
|
Title: Cafe Racer Project Post by paulmarshall on 09/26/14 at 21:09:33 Here are a couple of photos of where I am so far with the cafe build. I have modified the stock swing arm so the right side now matches the left. I have cut and tacked welded the sub frame. Both the swing arm and sub frame mods where from a donor savage frame. Will post more in depth photos of how this was done soon. I didn't want to start this thread until I was a way down the track but couldn't help myself. So this will be a long drawn out build. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/015_zps5c8a0922.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/018_zps25bfccdc.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/024_zpsd2e7d6b1.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/019_zps625737a5.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 09/27/14 at 04:07:01 Looks like the start of a great project. Balancing the left to right shocks is a great move. The stock bike hides the offset well - but it really shows on the Cafe and Bobber bikes. I mounted my license plate on the left side in order to make it less obvious. Dave |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 04:33:19 I have no idea the power required to operate the shocks nor do I know what theyre attached to, BUT, it sure Looks like a nice long lever for the shock to push up on.. You sure thats gonna stay straight? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 12:49:25 524D4B4C51566757675F4D410A380 wrote:
Like the original set up it will have bracing. It should be stronger than the original due to the steel rod being one continuous piece and not two pieces. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 14:03:04 Sounds like a plan. I think visually it would look better if you slid a pipe that just fits over the rod down it. A little brazing and they become one,,bongi,errrr bingo! |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 14:09:35 6F7076716C6B5A6A5A62707C37050 wrote:
Do you mean slide the pipe over the rod instead if using a brace? The rod I have used is 20mm thick same as the stock, It looks flimsy because of the lack of bracing. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 14:20:30 2C3335322F2819291921333F74460 wrote:
Yes with a thicker look using a pipe and a brace would look better. ;) |
|
Title: Re: Cafe Racer Project Post by Jeff71 on 09/27/14 at 18:56:28 That would be a great place to mount some discrete turn signals! Jeff |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 19:05:21 486764643533020 wrote:
Yes Jeff good idea. :) |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 19:15:44 Do you wish the rear end was higher? What is the plan on the rear fender? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 19:26:45 I modified the swing arm by cutting two swing arms in half and using the left side of both. I flipped one upside down and joined the two together using metal strips welded inside for bracing. I made a rear axle bolt 50mm longer than stock and a 50mm longer than stock right hand spacer. Lastly I bent some flat steel to cover for more strenght. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zps2cc38463.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/009_zps1cda6bcf.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/003_zps8f10047d.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zps9b0eba48.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/007_zpsfcb2e93c.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/008_zps70a27c87.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/018_zps12fee4b5.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/021_zps457060a9.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/025_zpsccbb72d0.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/008_zps7b4216c0.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/013_zpsa3aa08e1.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 19:29:44 5B444245585F6E5E6E56444803310 wrote:
Well I have some options about that. I can put longer shocks on like the Ryca kits but I wanted a level swing arm. When I sit on the bike I can only just put both feet flat on the ground so I think its high enough. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 19:32:07 Im going to run flat steel where the sub frame is so wont need a fender. But I still have the half fender from the bobber project that I could mount if required. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 20:12:51 Well,,IF there's room behind the seat for it,you Could rework where the shocks mount to the swingarm,bringing the shocks toward the center,shortening the top shock mount,but forcing the top mount up a bit,, The distance between the shocks,IMO,is just not attractive and IF I was putting the time in to build a bike, personally,I'd have to address that if at all possible. I'm not there and can't see everything,just that is what I'm seeing. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 21:09:40 No sir,, and Im not any kinda suspension engineer and Id be concerned about changing that angle that much. I have no idea how much more harsh the ride would be, but I suspect it would be. Im talking about reworking the lower mount so the bottom of the shock isant outside the swingarm but centered above it. Picture a BIG chain link,, 2 of them, like 2 washers welded together, a bolt thru the lower ones, securing them to the swingarm, and above, the shock. Then bend the now straight bar to allow for that height change, keeping the shock angle as is. Kinda a cantilever setup. It otta brace up easily & look okay, AND you wont be asking people Do these shocks make my butt look fat? I think youre on track for a nice lookin build. And I agree with the level swingarm look. I hope you can make it do that under load. I know that a bend would mean cutting the bar, but slipping it into a piece of pipe between the frame members.. with a few holes drilled to allow some brazing, grind it, bondo, bingo,, You got a torch, right? Bend it, toss it in some oil,, I have been known to tack things with solder, just to get them right where I want them,get a good mock up, then weld or braze them in. No 90* bends,, I think it would look sharp. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 21:17:46 Actually, by cutting the shock moounts off the swingarm and drilling it, running a pipe thru & welding it in, Then do the plates to mount it,, naah,, theyll move,, gonna hafta weld them on ,, Id definitely do the hole, pipe, to keep the swingarms integrity, then once the shocks were all set up, weld the plates to the swingarm, Just leave the bolt,, a well shaped plate would look fine,That way the distance between mount points wouldnt change much at all,, eliminate the tedious bends,, Mite even lower the seat a hair, |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 21:31:28 455A5C5B4641704070485A561D2F0 wrote:
I'm with you now. ;) I would have to re-lath the top mount but that wouldn't be a biggie, and would offer more strength being shorter. Ill look into it. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 22:24:02 Yeah,shortening it decreases the leverage,,measure the distance between the lower shock bottoms. Remount,measure,take that amount off one end of the top mount bar,,right? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 22:36:05 5D4244435E5968586850424E05370 wrote:
;) |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/27/14 at 22:45:06 I have just had a thought, I want to run a chain guard so shifting the mounting point to the top of the swing arm might get in the way. :( I will look into it though. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/27/14 at 22:47:35 I'll bet it'll work. The bottom of the rear sprocket is the pinch point.. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/29/14 at 13:56:28 My cheap back yard front wheel chock. :D http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zpsb0946498.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/29/14 at 20:10:20 Started playing with some cardboard to mock up the seat design. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/011_zps47c23b12.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 09/30/14 at 02:47:33 Before you get too far along...you should consider getting taller shocks that have more than the 1.5" of travel of the stock shocks. The extra travel makes the ride so much nicer. Dave |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/30/14 at 12:10:00 73484552434F545249414C53200 wrote:
Dave I have been thinking along the same lines which is why I brought these second hand shocks. But didn't like the angle of the swing arm. I could re-position the top mount. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/016_zpsd5666402.jpg I brought these last year when I was building the Bobber project which are more comfortable than the stock, which I was going to use. Im only using the old stock shocks for the fabrication process. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/009_zps77e7da54.jpg |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/30/14 at 22:23:16 How you gonna build the seat after you get the cardboard like you want it? I wish you could get a pic of one of those shocks held in place or maybe with the bottom in the mount.. Remember that post? If you're going to hafta move the top mount,hey... looks like a great time to make it narrower. Do these shocks sticking out make my butt look fat? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/30/14 at 23:00:24 0B141215080F3E0E3E06141853610 wrote:
Justin I'm tracing around the cardboard onto plywood, use florist foam between the partitions. Shave the foam to make a mold then lay fiberglass over and crack the mold when hardened. Similar to what this guy did but I will use florist foam not expanding foam. And I will remove the mold not leave it in like he did. https://www.youtube.com/watch?v=fsfSbL8cElk Still working on the shocks :) |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/30/14 at 23:09:35 Or do something similar to what our friend at HackaweekTV did to the Honda Sabre Cafe Project.https://www.youtube.com/channel/UC3v9cVoEt4YqZpGyzewdlrQ |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 09/30/14 at 23:20:34 I wanna see the long shock kinda In Place.. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 09/30/14 at 23:41:55 283731362B2C1D2D1D25373B70420 wrote:
If I mount the long shock with the existing mounting points when sitting on the seat I wont be able to touch the ground. I designed the seat higher so I could run a swing arm parallel with the ground. |
|
Title: Re: Cafe Racer Project Post by Dave on 10/01/14 at 04:00:56 I am not sure you are going to pull the Cafe' look off with the short shocks mounted so low on the frame. The traditional look has the top of the shocks right below the seat.....however folks are now doing the Cafe with mono-shocks and shaft drive bikes.....so I guess there are no strict rules on how it should be done. Most of the Cafe' or Street Tracker conversions for the Savage raise the rear by installing longer shocks - which does angle the swing arm, and then they lower the front. The seat pan is then built just a tad over the shock mounts. The way you are going the shocks will be way down from the seat. Having a nearly level swing arm is good for keeping belt and chain tension - but I am not sure how the end result is going to look. You are a very energetic guy.......How about lowering the mounting point for the swing arm? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/01/14 at 12:46:07 52696473626E757368606D72010 wrote:
You are right Dave, I may need to change the name to "Hybrid Racer Project". Moving the swing arm so it no longer is parallel with the ground is not a option especially running a small sprocket on the rear, because the chain rubs the front of the swing arm, where the swing arm bolt is if there is to much angle on the swing arm. Running the stock belt you wouldn't have this problem. I can move the top mount and fit longer shocks with no problem. Like Justin said I will temporary place the long shocks in place and see how they look. While still in the fabrication stage nothing is set in stone. I do like doing things a little bit different and try not to follow the norm, But do appreciate feedback and take it on board as I don't want to look stupid either. :) |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 10/01/14 at 23:33:47 You have a Savage,,you're set apart from normal,forever,already. Nah,not now,you already were. Getting the Savage just proved it. |
|
Title: Re: Cafe Racer Project Post by strang on 10/02/14 at 08:40:07 go white pipes |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/15/14 at 20:20:01 Did some work on the tank today. A bit of fiberglass work here and there. All ready for prime and paint. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zpsf45475ea.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/003_zps52517da5.jpg |
|
Title: Re: Cafe Racer Project Post by Spamy on 10/16/14 at 12:25:10 Looks good. But id say, ready for prime, sand, prime, sand, prime, sand, then paint. I bet that ends up being a little lumpy looking. darn bondo and shrinkage. I like that tank. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/16/14 at 13:29:58 4467767A6E170 wrote:
Yes Spamy you are right prime sand prime sand prime sand then paint.Something like that. ;) Im using Glaze putty over the Bondo to get a nice smooth finish. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/16/14 at 18:07:38 Making progress on the seat. I think I will use expanding foam. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/006_zps7cd38c86.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 10/17/14 at 04:56:51 Just use the wooden seat.....it's been done before! |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/17/14 at 12:12:50 59626F7869657E78636B66790A0 wrote:
Ouch that must be hard to ride without rear shocks. :'( |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/27/14 at 01:45:57 Used off cuts of wood to fill space so not to use too much expanding foam. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zps71d625de.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/27/14 at 01:47:39 Then used expanding foam. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zpsf4d8d61c.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/27/14 at 01:48:35 Trimmed the foam using a bread knife. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/009_zps8384a2ee.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/27/14 at 01:50:06 Filled in the holes with body filler. Ordering Epoxy resin tomorrow. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/017_zps6e50234e.jpg |
|
Title: Re: Cafe Racer Project Post by Michael L on 10/27/14 at 09:16:44 Inspirational build, good job on the swingarm! In my oppinion About the shocks, you really wanna get some longer ones, in order to get the rear end liftet up enough to provide the apropriate steepness/angle of the forks. Since it's born a chopper, it's quite an important factor when doing the savage cafe build.. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/29/14 at 22:47:44 Made and welded a bigger brace to support the rear break. 50mm longer than the original. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/010_zps0982d7c8.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/008_zpsad6068ee.jpg |
|
Title: Re: Cafe Racer Project Post by Spamy on 10/30/14 at 07:52:20 Are you going to use that seat as a mold, or the actual seat? Thats gotta weigh a ton. External molds are a pain. The finish comes out pretty gnarly. It adds a lot of sanding and finishing. From my experience, it would be worth it to use your seat and create a mold from it, then fiberglass that. Then the finish work is much easier. Actually after doing it a few times, its plenty worth it to pay 50-120 bucks for one already built. :) |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 10/30/14 at 12:27:11 Good point Spamy I may make a mold first then lay glass inside the mold for that smoother finish. I thought about buying a pre made seat but i find pleasure in both the journey and the destination. Plus I wanted to apply the 1,618 divine proportions formula shown here https://www.youtube.com/watch?v=oZ_rnmB2RBI . And wanted something different from the norm. Also I made the seat base wider for a more comfortable ride on long distance. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 11/01/14 at 19:15:06 Welded the top rear shock mount in place and fabricated a brace for the mount. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zpsfb481e9f.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 11/06/14 at 04:02:06 I was looking at they RYCA page this morning, and I saw that one buld feature on their site is also a fellow who markets their kits. He has come up with a brake stop that incorporates the brake light switch. This seems like a great solution and one that RYCA should start to build for their kits. The rear brake pedal really needs a stop......so that when you release the brake the pedal rests against ths stop and doesn't rotate upwards too far. Sorry about the photo not being too clear....it is from the RYCA website. |
|
Title: Re: Cafe Racer Project Post by caseyLA on 11/06/14 at 10:46:05 Here's the brake stop now included with the kits: http://shop.rycamotors.com/assets/images/productimages/rm-0577b.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 11/06/14 at 10:50:09 Good idea Dave thanks for the tip. ;) |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 11/06/14 at 10:56:52 303220362A1F12530 wrote:
That would work too Casey |
|
Title: Re: Cafe Racer Project Post by Dave on 11/06/14 at 11:17:01 252735233F0A07460 wrote:
Cool! I am glad that you have added that to the kit! |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/02/14 at 23:30:23 Haven't done much in the last few weeks but I have made a start on fiber glassing the seat. Got one layer of glass down. Used car polish for a release agent. Using Epoxy which needs 12 hours to cure. Two more layers needed I reckon. Will make a point to lay glass over the first layers joins to promote strength. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zpsf6dcc22d.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zps6c993a10.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/006_zps5d15765b.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/007_zps26fdada1.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 12/03/14 at 03:45:07 Looks good. You can put more than one layer of fiberglass on at a time....in fact it is best to do it that way as the layers are then bonded together. You can use some pins through the cloth and into the foam to hold the stubborn places down.....just be sure to pull them out before the resin sets up completely....and a little heat on the pin will help get them out. You could also use some wax paper and rubber bands or bungee chords or wrap tape around the wax paper to hold things in place. Or if you really are inventive....a plastic bag and a vacuum pump can really pull things together! It is also best to lap the fiberglass cloth over the seams so there are no joints - as the epoxy has very little strength without the cloth. The cloth can be cut and rolled over the edges, and you can also just pull fibers out of the matt and lay them over the seams and edges and work them down in place with a brush or roller. It is really going to be tuff to pull the fiberglass off the form you made. The vertical sides are going to make lots of friction and it is tall/deep. Also without a really smooth form and a gelcoat things are going to stick. Most likely you will need to tear your form apart......gasoline works really well to dissolve most foam and it won't hurt the fiberglass resin. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/03/14 at 10:37:46 Thanks Dave for the information, very useful. The weave mat I used was from a previous job and is very coarse. So coarse that it did not want to form around corners. When I tried to mold it around corners the weave started to lift where I had layed it on the flat side. I need to order more weave that is less coarse and more pliable to manipulate around corners. And like you said lay all layers in one go. |
|
Title: Re: Cafe Racer Project Post by Dave on 12/03/14 at 10:48:14 I admire the fact that you are willing to take on a task....and learn as you go. I have a nephew that never gets anything done.....as he is so worried about making a mistake along the way - that he never actually gets anything finished. He will begin the process....but never actually finish it as the first time he encounters some resistance.....he stops. Pretty sad.....he has tons of unfinished projects crowded in his bedroom, and that is pretty crappy for gaining any confidence or feeling of self worth. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/04/14 at 13:37:56 Might not be getting much done but I don't plan on getting it back on the road till next summer. Next winter for you guys on the other side of the world. How ever this hasn't stopped me getting more parts for it. A 1988 Kawasaki KZ 1000 Police Triple tree arrived today that supports a 38mm shock and stem bearings are the same size, that is heaps wider to allow my wider front wheel. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/001_zpsa7538e12.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zps0812fbe2.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/04/14 at 13:43:20 The only issue I have is that the KZ1000 Police Vintage Triples only support a 3/8 handle bars. I can mill the risers off and use clipons, But can anyone tell me could I drill out the handle bar clamps to support a 1" bar? I could then run Clubmans. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/003_zps1d3c8baf.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zps23472aac.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 12/04/14 at 13:50:24 I think you meant the bars are 7/8"....not 3/8". And I believe you can get Clubmens in 7/8". If you get painted bars you can weld on 1" pipe on the ends......if you plan on using the stock 1" controls. Or you could just shim your 1" controls. And....you maybe be able to machine out he 7/8" to 1"....the controlling factor would be the space between the bolts. Those bar mounts on the triple tree are massive however....and I think they would be better removed. |
|
Title: Re: Cafe Racer Project Post by verslagen1 on 12/04/14 at 14:54:12 4657435A5B5744455E575A5A360 wrote:
Take the top clamp off, put the bolts back and measure between them. If it's over 1" then yes, you can. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/04/14 at 20:09:38 I just need to confirm before others out there decide to do the same Triple Tree swap, The bottom bearing is slightly out. Top bearing of the KZ1000 is the same as the Savage at 25 47 15. The bottom bearing for the Kz1000 is 28 52 16 and the Savage is 30 55 17. I am going to mig weld some metal around the bottom of the stem and then lathe it down to 30. Does anyone know if I could cut corners by using the 30 55 17 bearing over the 28 stem. I know its naughty but once its all pulled together and tightened down it might work? I will order the bearings and slide it down the 28 stem and see how much movement there is. But to be honest I will prob go with my first and safer option. |
|
Title: Re: Cafe Racer Project Post by gizzo on 12/05/14 at 00:11:21 Hi Paul. Ignore this if it's teaching you how to suck eggs: Just a few ideas about fibreglassing the seat. The chopped mat you're using is most likely designed to be used with polyester resin. The mat comes impregnated with a binder that dissolves in polyester resin. Epoxy doesn't dissolve the binder so the cloth stays stiff and is hard to wet out. If you can lay your hands on some 6 oz fibreglass twill weave, try it. It drapes around curves brilliantly. It would probably be good for your seat. Loose weave would work well, too. Dave mentioned vacuum bagging: You can make a vac pump from a coffee tin and aquarium pump for very little $$ and an outdoor bin liner as the bag. I used the fish pump for a while before I converted a nebuliser. I'll PM you a good link if you're interested. If you can't pop that piece off your mould, you can try splitting it down the centre, pop it off in 2 halves then join them back together afterwards. I'd have carved the plug from white foam, glassed it and melted the foam out with acetone or petrol, but that's just me. Anyway, good luck with the build. |
|
Title: Re: Cafe Racer Project Post by Dave on 12/05/14 at 03:23:03 Gizzo....I like the aquarium pump tip! I have one that I use when I am drying out fuel tanks, and now I can also use it as a vacuum pump - Brilliant! ;) I also didn't know that about the fiberglass matt....good to know. My fiberglass experience is limited to using the little kits you get at the auto stores where everything is in the box. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 12/05/14 at 11:09:33 564C484A4B75445751574C414240250 wrote:
Thanks gizzo, what you say about the mat makes perfect sense. I did buy that mat for a earlier project with polyester resin, but did not know it came with a binder that breaks down with only polyester resin. Any way its hardened nicely and has made a good strong base. I have got some Woven Roving which forms to corners really well, and will lay 3 or 4 layers of that to strengthen it. Funny you should mention it I way only yesterday thinking this is going to be fun trying to get this out of its mold. My thoughts was to cut a hole in the bottom where the hump is and pull the guts out that way. Its only wood and foam. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/02/15 at 22:47:47 Removed the mold from the seat hump today. Took a little bit of doing but with some clever use of a skill saw and some Acetone to dissolve the foam mission accomplished. I will leave the ply in the seat section drill holes for mounting bolts and glass over it. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zps12b98084.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zps759fd3cb.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/007_zps3fdedff7.jpg Still need to clean it up. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/008_zps4910a4aa.jpg |
|
Title: Re: Cafe Racer Project Post by Skiprrdog on 01/04/15 at 17:32:36 Sssssmokin! |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/09/15 at 20:09:23 Cleaned up the seat today. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zps450e5bfb.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/09/15 at 20:11:16 7 inch metal case headlight arrived from England today. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zpscca8bb89.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zpsd3bbd046.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/20/15 at 10:46:34 Slowly gathering more parts. ;) Brought this Starter Idler Gear off EBay for $45 USD. Seller claims it is new . http://i.ebayimg.com/00/s/MTE5NVgxNjAw/z/abMAAOSwDwtUrB8v/$_57.JPG |
|
Title: Re: Cafe Racer Project Post by Dave on 01/27/15 at 04:22:03 Any update on your powder coating adventure? |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/27/15 at 10:38:19 1B202D3A2B273C3A2129243B480 wrote:
Hi Dave not yet waiting on powder to arrive from Eastwood. Contacted the last week and they said it will arrive here on the 29 Jan. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 01/28/15 at 22:40:05 Because in NZ our volts are 240 so I had to buy this reducer to use the powder coater. It arrived today. All Im waiting on is the powder. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/001_zpsp67burpr.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/08/15 at 19:21:14 My first attempt at powder coating today. I used a powder called "Silver Vein", it looks like hammered steel. I'm going to do the hubs and rims in Silver Vein. Because hubs and rims get dirty easily this colour/color will hid a lot of that, and I hate it when I get done polishing wheels for them to get dirty. I coated the front break rotor for practice. Before I started http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/001_zpswttqyosr.jpg After a media blast http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zps90sefcsp.jpg After powder coat http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/022_zpsa4dy22j0.jpg After applying clear gloss powder http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/014_zpsyxgpep4a.jpg |
|
Title: Re: Cafe Racer Project Post by jcstokes on 02/09/15 at 00:56:13 That's good, even for us stock people, there's too much cheap poor quality chrome and poorly protected polished aluminium on our stock bikes. |
|
Title: Re: Cafe Racer Project Post by Dave on 02/09/15 at 04:13:52 That looks really nice. The local powder coating folks have a "chrome" that looks just like real chrome with the silver powder baked on - unfortunately it has to be clear coated to be durable and when the clear is added....it loses a bit of the chrome look. Still, it is a very nice look and is far more durable than the un-coated aluminum. |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 02/09/15 at 05:40:11 If you're gonna unlace the rims and get the hubs in hand, get the grinder on the front one. If it's like mine it has all kindsa stuff poking out,catching crud. I wanted to get in there,clean it up and hang a leather strap on it to keep it wiped off, like I did on a bicycle. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/11/15 at 16:23:16 My second attempt at Powder Coat way a huge success. I know a lot of members here don't like the chrome engine covers, but I do because it adds bulk to the engine. Each to their own. How ever I have powder coated one to see how it looks and now I am going to powder coat more engine parts with Silver Vein. I will be redoing the break rotor to get the same results again now I know what to do. I'm pretty happy that I am getting professional results on my second attempt. Watching heaps of YouTube has helped. Before http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zpsaprinwyq.jpg After http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/021_zpsyksuacbn.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/013_zpswury76gv.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/012_zpsc4cvipev.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/011_zpsgipy0az8.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/010_zps0srgovkt.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/022_zps3ymwy380.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/019_zpsphpevwr5.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/015_zpshkhw6fn3.jpg |
|
Title: Re: Cafe Racer Project Post by Kris01 on 02/11/15 at 17:53:41 What an improvement! I'd like to see a pic of that installed on the bike. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/14/15 at 17:35:20 Powder Coated the other engine cover http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/011_zpsdp5wtali.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zps4j2wjiqz.jpg Also both inspection covers http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/027_zpsokpwmuji.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/031_zpsxhcyhuxv.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/14/15 at 17:40:26 Can someone please tell me if the rubber and silicon seal around the oil spy glass will stand up to 375-400F for 20 min intervals which the Powder process requires? http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/023_zpshjylqafh.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/022_zpsid0qkqvk.jpg |
|
Title: Re: Cafe Racer Project Post by justin_o_guy2 on 02/14/15 at 22:36:26 I'm going to say NO,won't survive. BUT,I Do believe that lens is available as a replacement part, and if that is true,then,well, you do the math. |
|
Title: Re: Cafe Racer Project Post by Martin71RS on 02/14/15 at 23:20:53 wow, that looks good....there's another thing on my wish list.... |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/14/15 at 23:52:31 435C5A5D40477646764E5C501B290 wrote:
I was thinking I could remove it but wasn't sure I could get the same seal. The outer rubber ring looks easy to replace but the inside looks like some kind of silicon. Not sure what kind of silicon to use. I could take it into my local shop and ask. I have a spare engine cover so if I mess it up its no biggie. But like you say Justin if the parts are available then surely they can be replaced. |
|
Title: Re: Cafe Racer Project Post by Martin71RS on 02/15/15 at 03:32:33 If you get it out in 1 piece (should be possible) just put it back in with black rtv sealant, I believe the glass sits in a rubber. |
|
Title: Re: Cafe Racer Project Post by Dave on 02/15/15 at 05:33:01 When I took my clutch cover off, that applied silicone seal had decomposed and I just pulled it off with my fingers. I pulled it off, cleaned the area up, and applied a new layer of silicone. |
|
Title: Re: Cafe Racer Project Post by nof1 on 02/15/15 at 09:06:24 I'm digging the info and inspiration. Cheers |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/22/15 at 17:18:18 My new 16x3.00 front rim arrived from England today. Will be bead blasting and powder coating soon. Still slowly gathering parts. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/006_zpsqxjigga3.jpg |
|
Title: Re: Cafe Racer Project Post by Dave on 02/23/15 at 03:37:38 That looks like an awful lot of spoke holes.....maybe because it is a 16" rim. Have you counted the holes yet? 36 will work.....40 won't. |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/23/15 at 10:36:03 42797463727E656378707D62110 wrote:
I thought that too when it arrived. Yes there are 36. :) |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/24/15 at 23:53:42 Powder Coated the oil filter cap.Will be doing the rest of the clutch cover soon. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/007_zpsjanvqayn.jpg |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 02/28/15 at 18:51:07 Been baking today. Fresh out of the oven. Sorry not scones but a clutch cover. http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/002_zpssoyqzlfm.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/003_zpsrjvu4d5t.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/004_zpspbticlsz.jpg http://i1300.photobucket.com/albums/ag91/PaulMarshall1977/005_zpshyxc8jm5.jpg |
|
Title: Re: Cafe Racer Project Post by Martin71RS on 03/01/15 at 09:38:12 very nice!! 8-) and how did you get the sight glass out? |
|
Title: Re: Cafe Racer Project Post by Art Webb on 03/01/15 at 09:58:34 Yum! |
|
Title: Re: Cafe Racer Project Post by paulmarshall on 03/01/15 at 10:59:45 1B3724223F3861670405560 wrote:
I used a Stanley knife to cut around the sealant on the inside of the clutch cover. I kept running the knife around the glass cutting deeper and deeper until I was able to push the glass out. I was gentle because I thought I could reuse the glass but later realized that reusing it is not possible. Not for me anyway. |
|
SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved. |