Project Cafe

[beergood]

I just went back and re-read your first post. February seemed pretty far away back then, didn't it?

What are you thinking about doing to the rear of your frame where you made your cuts. I am trying to figure out what to do with the open tubes. Got a few ideas, but I am curious what you are thinking.

 

[jonesti]

I was thinking about glassing up some end caps....but I really don't know yet.
February, no doubt, I guess 08'!

 

[80GS1000]

I have the same issue from where I cut off the passenger peg mounts. Thinking of placing a plug of Bondo maybe half an inch to an inch inside the open tube, and letting that harden. Once there's a "base" to work with that won't move inside the tube, I'd put enough Bondo to fill the end part of the tube and make a nice vertical plane that's flush with the end of the cut metal. Then sand and paint. No idea if this will work yet though.

 

[jonesti]

PJ, I'd really suggest welding that spot up instead of using fillers. With the flex in that area I'm willing to bet it'd crack/pop out plastic filler in no time. But if you were going to use filler I'd probably use JB Weld as the plug than to smooth the rail this stuff http://www.eastwoodco.com/shopping/...DUCT&iMainCat=516&iSubCat=518&iProductID=5594
But if ya, can weld it!
I completely forgot to weld up the holes before I sent it to powdercoat. Trying to get it done in a hurry!

 

[jonesti]

By the way your bike is coming along really, really nice!

 

[80GS1000]

PJ, I'd really suggest welding that spot up instead of using fillers. With the flex in that area I'm willing to bet it'd crack/pop out plastic filler in no time. But if you were going to use filler I'd probably use JB Weld as the plug than to smooth the rail this stuff http://www.eastwoodco.com/shopping/...DUCT&iMainCat=516&iSubCat=518&iProductID=5594
But if ya, can weld it!
I completely forgot to weld up the holes before I sent it to powdercoat. Trying to get it done in a hurry!

By the way your bike is coming along really, really nice!

Good idea, I'll have the holes welded up when the welder comes by to permanently attach the upper monoshock mount to the frame. And thanks for the compliment!

 

[jonesti]

Quick update of Sunday's activities. Made new bushings for the ZRX shocks to fit. That's it, no pics. Still waiting on shims and tires to come in so I can start to really assemble!

 

[80GS1000]

Quick update of Sunday's activities. Made new bushings for the ZRX shocks to fit. That's it, no pics. Still waiting on shims and tires to come in so I can start to really assemble!

Nice work on the bushings. I know that antsy feeling waiting for parts to arrive all too well. :lol:

 

[dardoonk]

Well, the stock rear brake setup has been bothering me. The added weight of the enormous stock caliper and the thick ass 275mm disk had to go. So I just bought....

and

more fab work....deadline gets pushed further back...stop me, please!

jonesti, Just wondering how you plan to mount that rear disk on your wheels?
I've got a an '04 GSXR750 caliper & master cylinder, but need to figure out how to get a 220mm rear disk on there.

 

[jonesti]

Looking like I'll be scratching the rear brake setup for the moment. But it's close to the same as the front. My plan is to have an adapter plate machined, similiar to what you use converting a 6lug to 5lug wheel assembly on cars and trucks. For the front the plate will be 110mmOD, 51mmID, and 8-10mm thick. Chamfer the holes and use flat socket cap screws to button it up. Also, for the caliper carrier, you'll have to either adapt the stock one and add some sort of brake torque arm mount or machine up a new one carrier altogether. Good luck to ya!

 

[jonesti]

Lets see...got the tires in today. Avon AM26's. But may have screwed up?? I order a 120/90 for the rear and it appears it's gonna be a tight fit, but I'll give it a whirl. Maybe add a link to the chain, we'll see! Still waiting on the shims so I can get down to work on buttoning up the engine tune-up. Then I can start cooking on the final assembly and body/paint work.

 

[jonesti]

Got the Avon tires mounted and balanced. It looks like there isn't going to be a swingarm clearence issue. But that's all I've managed. I got some type of really cool respiratory infection from one of my germ bag kids. Aren't they grand! So I've been on the mend for the last week or so.
Still waiting for the shims. I ordered them from Cycle-recycle II on 2/14 and still nothing. I've sent a few emails asking for a shipping/tracking notice with no response and I have tried calling but the line stays busy??? I know a number of folks here have recommended them so who knows?
I really want to get the engine all wrapped up before moving ahead.

 

[jonesti]

Ask and you shall receive....Got hold of Cycle-recycle II looks like they were short on a couple of the shims I needed so they were holding on till they got them all in. Looks like they are being shipped this afternoon.

 

[jonesti]

Time is just ticking by and the weather is only getting better! 70's for the last week or so....oh well. Finally got the valves to spec and dropped the engine in. In the process I managed to take the max amount of powdercoating off! Luckily it's in a unnoticeable location.

NERD ALERT

 

[UncleMike]

Lookin' good. I love that paint scheme.

 

[beergood]

Nice. When do you think you'll have that running?

 

[jonesti]

Lookin' good. I love that paint scheme.

Thanks. I really like it too, but it's getting a fresh coat and new colour!

 

[jonesti]

Nice. When do you think you'll have that running?

?? Just need a Dyna S and to re-wire for the engine, but for the whole package who knows. The front rotor is goning to be the biggest pain in the neck. It looks like I'll need to water jet a new carrier, yeah..:?

 

[byrdman76]

In my best BORAT impression...

In my best BORAT impression...

veddy nice!

The black rims look sweet. Did you have to modify the shocks at all?

 

[badbrown]

What tire sizes do you have now? Is that what's in the pic? Did you stay with the 19" front rim?