1. Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

bensalf's 4 year caferacer build

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

  1. Urra

    Urra Member

    Messages:
    46
    Likes Received:
    1
    Trophy Points:
    8
    Location:
    Miami, FL
    This makes me want to take my bike apart ten times over and scrub with a nylon toothbrush until everything is spotless>.< I wish I had these tools! Awesome work mate
     
    jordan smith likes this.
  2. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    /\ --- /\ ---/\---/\
    thanks for your comments ;)

    having some problems with photobucket at the mo, I may have used up my allotted space,
    although it says I have only used 28 %? be back soon!!
    stu
     
    Last edited: Jan 22, 2016
  3. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    onto the airbox now.
    I wanted to keep the area at the back of the engine , under the seat, as clear as possible ,to create that open look, that is recognised as a café racer.
    but at the same time didn't want to go down the "pod" route.
    so I made provisions to house all the electrics in a shallow underseat tray, and to move the battery back into the seat "hump".
    so next to modify the airbox, to make it smaller and much shorter.
    so I cut the air filter housing ,away from the airbox.
    [​IMG]
    enlarged the hole to take a circular filter
    [​IMG]
    this filter is for a Honda 90------oh well ---nothing ventured.
    [​IMG]
    enlarged the hole in the filter to allow more air
     
  4. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    [​IMG]
    made a plate to mount the filter to the airbox
    [​IMG]
    here's the filter mounted inside the airbox
    [​IMG]
    plate cut out and mesh and venturi fitted
    [​IMG]
    stu
     
  5. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    here's the modified airbox sprayed up and fitted in frame
    with filter about to be screwed in
    [​IMG]
    [​IMG]
    here's the airbox all finished with venture fitted
    [​IMG]
    incase you're wondering where I got the venturi,
    its -----er-------- a cooling fan venturi ,from inside an old computer tower system
    stu
     
  6. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    next the under seat tray to house the electrics, these will be .......
    battery, tci unit, reg/rectifier unit, battery isolator, card reader ignition , fuse box, ignition relay, voltage regulator for card reader. and starter solenoid
    also rear reservoir for rear brake ,and tool space.
    obtained some 1.5mm alloy plate

    [​IMG]
    here's the tray polished and bent to shape with corners welded up, cut outs for frame tubes done
     
  7. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    [​IMG]
    here it is in the early stages, test fitted to frame, also added the small alloy angle, for the seat rails.
    [​IMG]
    researched the sizes of batteries and amp/hour ratings on the "yuasa" website, and made a block of wood ,the same size as the battery will be, as a test fit for the seat to fit over
    [​IMG]
    stu
     
    k-moe likes this.
  8. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,613
    Likes Received:
    6,706
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    You are making the winter easier to bear.
     
  9. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    ha,ha, yes I'm already well into my # 2 xj600.
    [​IMG]
    stu
     
  10. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    back to the tray, here it is with the seat hinged back over, the battery-- er---block of wood, and concealing the tray.
    [​IMG]
    and here it is on its final fit
    [​IMG]
    here's the tray , later , filled with the gummings.

    [​IMG]
    stu
     
  11. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    now , onto the exhaust and footrest hangers.
    this is the original pig-iron hanger, so I decided to move the footrests back, and up ,to make the caferacer position easier with the
    new clipon and lowered handlebars, to give the laid down look.
    so the hangers had to go.
    [​IMG]
    I mocked up some hangers out of white conti-board. to try the position.
    also I bought 4 shorty silencers, so I could have 4 stainless steel exhaust pipes custom made, into a 4 into 4 system
    [​IMG]

    [​IMG]
    [​IMG]
    at this , I loaded up the bike, and took it 80 miles to a firm of stainless steel fabricators to have the 4 pipes made.
    they had the bike over a month, as they are normally out on site ,making stainless steel pipes for the food industry.
    bikes are their spare time work.
    eventually collected the bike with the pipes fitted, all pipework was tucked underneath the bike as instructed.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    stu
     
  12. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,613
    Likes Received:
    6,706
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    Hey now...those hangers are made from the highest quality pig-ALUMINUM. ;)
     
  13. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    -------------------------------------------------------------------------------------------------------------
    Hey now...those hangers are made from the highest quality pig-ALUMINUM. ;)
    --------------------------------------------------------------------------------------------------------------

    quite right!!----- but they're piiiiiiiiiiiig ugly:eek:
    stu
     
  14. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    I obtained some 10mm alloy plate from a local scrap metal dealer," quite cheap".
    after reshaping the wooden hangers I made, and working out where the pivot point should go for the gear linkage and brake pedal, I marked the shape out onto the plate.
    [​IMG]
    [​IMG]
    first test fit on r.h. side
    [​IMG]
    extra holes drilled and started to polish up
    [​IMG]
    here it is fitted ,with brake pedal and master cylinder fitted and footrest bracket and exhaust bolted on.
    [​IMG]
    l.h. side, with pivot hole for gear linkage ,footrest bracket and exhaust hanger
    [​IMG]
    stu
     
  15. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    now for the gear linkage, as I moved the footrests backward and upward, then the original lever would not reach my foot.
    heres the original set up
    [​IMG]
    note the lever moves on a dummy shaft and is not fitted directly on the splines.
    so I needed a longer linkage, and also to keep the linkage away from my foot I needed a lever with the pivot on top.
    I managed to find one on ebay , from a Kawasaki gp500, that was the correct orientation, and length, also it meant the gears were still in the original place.
    i.e. 1 down and 5 up
    [​IMG]
    cleaned up the lever and had the linkage rechromed
    [​IMG]
    result.
    stu
     
  16. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    onto the chain guard, which is a bland plastic one.
    [​IMG] [​IMG]


     
  17. jayrodoh

    jayrodoh YimYam Premium Member

    Messages:
    2,523
    Likes Received:
    1,103
    Trophy Points:
    113
    Location:
    Cleveland
    Stunning work!
     
  18. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    /\---/\---/\---/\
    thank you for your comments, apologies for some of the blurry pictures.

    decided to make a new chainguard form ally plate.

    marked out the shape of the plastic one ,onto the plate ,and cut it out.

    [​IMG]
    drilled some holes along the length, and bent it to shape.
    [​IMG]
    wired the bent bit at the end, and had it ally welded up
     
  19. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    [​IMG]
    polished up and fitted.
    [​IMG]
    [​IMG]
    stu
     
  20. bensalf

    bensalf Well-Known Member

    Messages:
    1,274
    Likes Received:
    258
    Trophy Points:
    83
    Location:
    yorkshire ,england
    next onto the oil cooler. matrix was pretty well mashed up
    [​IMG]
    split a clothes-peg in half ,and shaved the ends down, and began the painstaking task of straightening each fin out,

    [​IMG]
    nearly there
    [​IMG]
    [​IMG]
    done what I could, and sprayed up
    [​IMG]
    also found out the oil cooler pipe ends are brass!!, polished these up
    [​IMG]
    made a mesh guard for the front of the cooler
    [​IMG]

    stu
     

Share This Page