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bensalf's 4 year caferacer build

Discussion in 'XJ Modifications' started by bensalf, Dec 26, 2015.

  1. bensalf

    bensalf Well-Known Member

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    Good on ya admitting to the mistake and the consequences. Another person will read this thread and save their valves :D
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    yep I hope so , I think I got away lightly, especially dropping on that spare engine so easily.
    luckily my "big bro" is an engineer ,and has all the machines, and he has managed to straighten the bent valves.
    which I will replace in the spare engine, and rebuild it.
    but at the time I did this, he was away on a 12 week cruise.
    stu
     
  2. bensalf

    bensalf Well-Known Member

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    now I got the engine built up and showing decent compression across all 4 cylinders, valves in spec-- again.
    I started to polish up some of the engine covers,
    here are some in various stages of polishing.
    [​IMG]
    I polished these covers ,similar to the wheels, starting with 400 grit paper ,wet , then 600 ,1000, 1500, then buffing wheel with brown soap then
    green soap,
    I spent literally weeks doing all the covers.
    cam cover completed

    [​IMG]
    clutch cover done
    [​IMG]
    generator and crank covers polished and painted in the lettering
    [​IMG]
    covers now finished and new stainless steel allen screws obtained
    [​IMG]
    stu
     
  3. bensalf

    bensalf Well-Known Member

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    starter motor stripped and cleaned, there was still plenty of life left in the brush ,so I polished the cover an rebuilt it
    [​IMG]
    cam cover donuts were pretty much done in , got new ones and fitted on bolts .
    [​IMG]
    [​IMG]
    had cover bolts chromed
    silver painted the 4 large ones with the fixed rubbers,
    [​IMG]
    stu
     
  4. bensalf

    bensalf Well-Known Member

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    decided to do something different with the sprocket cover.
    [​IMG]
    I cut out 2 of the cast circles
    here it is at bottom right, after removing paint
    [​IMG]

    [​IMG]
    also cut away part of the upper plate
    [​IMG]
    rounded off the edges and began sanding down

    [​IMG]
    polished up the cover and red painted the cut away edges
    [​IMG]
    here it is fitted at a later stage
    [​IMG]
    stu
     
    ecologito likes this.
  5. bensalf

    bensalf Well-Known Member

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    engine now fitted in frame, had engine plates and bolts, chromed
    [​IMG]
    found these, cast ally, headlight brackets on ebay, polished and fitted.
    [​IMG]
    [​IMG]
    also found some clipon, 2 piece handlebars
    [​IMG]
    stu
     
    Franz and Quixote like this.
  6. quebecois59

    quebecois59 Well-Known Member

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    woooow! very nice work
     
  7. bensalf

    bensalf Well-Known Member

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    woooow! very nice work
    ------------------------------------------------

    thank you very much for your comments, I have'nt had many replies so far, its nice to get some feedback from some of the experts.
    probably because its in "modifications"
    this is my first xj, although I've cafe'ed some other bikes in the past.
    I'm already onto my second xj600 now , but that will be in standard form.
    here's a honda cx500 I did 25 years ago

    [​IMG]
    stu
     
  8. darren ditmar

    darren ditmar Member

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    great job so far. inspiring me to go with a polished looked on my motor instead of black
     
  9. rocs82650

    rocs82650 Well-Known Member

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    Exceptional craftsmanship. I vote to add this to the build threads in the Information Overload Hour.

    Gary H.
     
  10. icedog75

    icedog75 New Member

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    Can't believe you haven't had many comments....I'm just starting my work and though I may stay pretty close to stock there's a lot to be inspired by here and a lot of good process info. Great work.
     
  11. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Excellent idea, consider it done.

    Beautiful work, I think you give Wizard and BigFitz a run for the money........
     
  12. bensalf

    bensalf Well-Known Member

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    Beautiful work, I think you give Wizard and BigFitz a run for the money........
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    oh ,no , they're way above my league.
    I only got this far ,from litening to them, and reading , (and taking heed) of all the info on here.
    thank you all for your comments so far
    stu
     
  13. rocs82650

    rocs82650 Well-Known Member

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    Thanks. I think future members will enjoy this build as much as the others. Camelman and Salty Dog's 1100's is another one of my favorites.

    Gary H.
     
  14. bensalf

    bensalf Well-Known Member

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    so-- on with the build,
    and so to the er, -----carbs--------- the subject of so many posts on here.
    and I can only endorse the advice in "the church of clean" and the whole 9 yards.
    they were in a bit of a state, throttle shafts were seized solid.
    [​IMG]
    soaked the throttle shafts in paraffin overnight, and managed to free them off.
    [​IMG]
    broke the rack apart and started to strip each carb
    [​IMG]
    whilst stripping the carbs down , I noticed this tiny ball bearing ,on the bench towel. I hadn't a clue where it came from, and there was no reference to it in the Haynes, or on here, you can see it here at the end of the ruler
    [​IMG]
    then I found another bxgger,so I had to take a closer look at the carbs.
    and this may help others working on carbs
    [​IMG]
    what I found ,was that where the enrichment shaft slides through each carb, on #2 and#3 carbs, there is a tiny spring and ball ,that locates in a notch on the enrichment shaft ,to keep it in position, very lucky I found these
    [​IMG]
    [​IMG]
     
  15. 81550Seca

    81550Seca Member

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    This is all looking f'ing pretty!
     
  16. bensalf

    bensalf Well-Known Member

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    continued to strip each carb
    [​IMG]
    marked up the butterflies for which way round and which way up
    sprayed up the carb bodies, new throttle shaft seals obtained, cleaned all passages in each carbs,
    started rebuilding carbs
    [​IMG]
    wet set the floats using a plastic jug I made to fit under each carb, using a dummy tank, to fill the jug, and allow the floats to rise
    [​IMG]
    sprayed up the carb brackets ,also had the middle 2 carb hats chromed, and stainless steel screws fitted all round
    [​IMG]
    [​IMG]
    stu
     
  17. Polock

    Polock Well-Known Member

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    Damm, you do nice work. Are you really going to ride it?
     
  18. bensalf

    bensalf Well-Known Member

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    onto the carb to head boots, they weren't in too bad condition, but had slight cracks on the outside, but not all the way through. new ones were almost £100
    and good used ones were unobtainium. so I decided to repair them, I've seen the innertube method used on here, but as I was an electrician by trade in my working days
    I looked into getting some heatshrink tubing to do the job.
    I got hold of some 4" tubing with 7 times shrink ratio.
    [​IMG]
     
  19. bensalf

    bensalf Well-Known Member

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    Are you really going to ride it?
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    already have, only done about 50 miles last year before the weather turned bad.
    stu
     
  20. bensalf

    bensalf Well-Known Member

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    test, tried a piece on a scaffold pole
    [​IMG]
    shrank it with blowlamp
    [​IMG]
    all seemed ok . so onto the boots
    cut some strips the same width as the boots ,put a pin hole in to slot over the vacuum tube.
    [​IMG]
    smeared some black silicon sealant over the boot spigot and shrank the tubing on, but just enough to grip the boot.
    [​IMG]
    all 4 done and blanking caps fitted to the vacuum tubes
    [​IMG]
    test tried boots onto carbs, all ok
    [​IMG]
    stu
     

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