The BOSS - Cafe racer build

[Guest]

I only have a closet now.

I used to have kitchen table and sink

Ahh the single days

 

[JvZ]

Thanks guys, it makes my garage feel like a castle.

It was way too cold to spend too much time in there this weekend. But I did manage to do some assembly done and made a start on the wiring too.

My forks are at the chromers so I managed to pick these up on eBay for a couple of quid.

They are just temps until I get my originals sorted.

Here is the progress so far, keep in mind that both sets of shocks will be replaced

I also got the old gunk and dead tape off the loom.

 

[Agemax]

looking good, i like the seat. how are you going to sort the wiring loom now, heat shrink or tape it up? i would recommend heat shrink tubing for a longer lasting,more professional look

 

[Dec79]

Good progress dude, rep+ as it's cooooooold out there!!!

 

[JvZ]

Slow progress

Slow progress

Sorry for the lack of posting, been doing a lot of work but it really is not looking like much, I am on version 3 of the seat and it is starting to show some potential but hardly looks any different from the last post

 

[JvZ]

looking good, i like the seat. how are you going to sort the wiring loom now, heat shrink or tape it up? i would recommend heat shrink tubing for a longer lasting,more professional look

I am actually going for a combination, I hate electrical tape, in my mind it is only ever a temp solution, but I am struggling to het the HS over the connectors and then to still shrink to a decent size, I really don't want to have to cut the connectors off and solder. I really struggle with soldering on my own and I can see myself taking things off and moving them around a lot so connectors are going to be the way to go.

I found some self-amalgamating tape, for waterproof connections, so I will use HS where I can and the SA tape over normal electrical tape for I have already fixed up a few questionable and broken connections and covered these with HS so, so far so good.

Hopefully no electrical gremlins will creep in, hoping to test some electrics next weekend. That is if I can get the seat finished.

 

[JvZ]

Distraction

Distraction

Does anyone else have this problem... I keep looking at my donor motor and carbs and start thinking of another project. I am a completed-finisher at heart so won't act on this impulse just yet but I do find myself trolling eBay looking at frames and wheels

 

[salty_monk]

I am actually going for a combination, I hate electrical tape, in my mind it is only ever a temp solution, but I am struggling to het the HS over the connectors and then to still shrink to a decent size, I really don't want to have to cut the connectors off and solder. I really struggle with soldering on my own and I can see myself taking things off and moving them around a lot so connectors are going to be the way to go.

I found some self-amalgamating tape, for waterproof connections, so I will use HS where I can and the SA tape over normal electrical tape for I have already fixed up a few questionable and broken connections and covered these with HS so, so far so good.

Hopefully no electrical gremlins will creep in, hoping to test some electrics next weekend. That is if I can get the seat finished.

What about the fabric tape?

http://www.ebay.com/itm/Factory-Electrical-Wiring-Harness-Cloth-Tape-OEM-NOS-M-/200606918488

BMW do one too... http://www.ascycles.com/Illustrated...pair/61_1998?gclid=CO7Ojtrn_LUCFetAMgodI3YAoQ

I would go for the 3M over a generic brand as the glue will be better..... Period for a cafe racer, better abrasion resistance. I have tried SA & the problem is at points where it touches it wears very quickly.
The trick with electrical is to get the best quality you can find (Scotch, 3M etc) and don't leave an "end". Always wrap the tape back a couple of wraps & then over so that the end of the tape is not at the end of the wrap but an inch or so back.

 

[peels]

very nice!

Particularly like the wheels....that's what I was thinking I would do when/if I do a GS. Looks nice...

is that powder coat, or rattlecan?

 

[JvZ]

Thanks Peels, so far everything has been rattle can mostly with the simoniz tough satin black

@salty, that looks like a great option, I will see how I get on with the stuff I have and might finish off with the fabric stuff, it looks pretty cool

 

[wally]

Your project should be taking off nicely, pretty soon.

I assume your weather is clearing up slightly.

 

[JvZ]

Thanks Wally. So far our spring has been like a Cape Town winter, except with more snow! I am starting to miss KZN!

I got quite a bit done his weekend, but as it was mostly getting wiring to work (broken earth wire had me cursing for hours) and getting some foam and fittings on the seat. Not much visual change but I'll get some pics up soon.

 

[JvZ]

Just found out that I am getting my fork stancions back on Monday . Anyone got any tips on what oil to use or any other tips for rebuilding the things? I have some brand new seals, ready to go and will also change o rings etc. I am not going to splash any cash on progressives just yet, that will be on the to-do list for a little while

 

[JvZ]

Found in my sump

Found in my sump

Okay, not the match stick, that is there for scale, but loads and loads of ground up plastic, most of it is the colour and size of beach sand. Any ideas? The reason the PO stopped using the bike was because it was jumping out of second gear?

Any theories? My problem is that if I strip the engine, how on earth do I know what to replace?

Btw, I had a peak at the gears and there are no obvious signs of damage there.

All advice appreciated!

J

 

[Agemax]

most of it could be just flakes of sealant used on crankcases etc when assembled.
or fragments of old gaskets

 

[JvZ]

most of it could be just flakes of sealant used on crankcases etc when assembled.
or fragments of old gaskets

I don't think so, this is hard, brittle stuff. Strongly suspect it is some bush or fitting or something. I have a lot more work to do on the chasis so the engine is going to have to wait. There was loads of sealent in there though. The oil strainer/pickup was pretty clogged.

 

[JvZ]

Fork me

Fork me

Just found out that I am getting my fork stancions back on Monday . Anyone got any tips on what oil to use or any other tips for rebuilding the things? I have some brand new seals, ready to go and will also change o rings etc. I am not going to splash any cash on progressives just yet, that will be on the to-do list for a little while

Right, just got them back and they look awesome, :dancing: I see a rebuild on Easter weekend. Anyone have any recommendations on which oil to use, or should I follow the handbook (I'm sure there must be some advances over the recommendation printed over 3 decades ago)

 

[Agemax]

any decent oil is good enough nowadays. i use Silkolene oil but thats just my preference, everyone will have their own. or just buy the best they have available in the shop.
oil weight again is personal preference. go for around 15 or 20w oil as a middle of the road choice or if you want slightly softer or harder forks (depends on rider weight, riding style etc.) then go for 10w or 25-30w.

 

[JvZ]

Not much progress lately, life has been getting in the way a bit and a few hiccups with the build have been a bit demotivational. Anyway I am almost finished helping people floors down, going to kids birthday parties etc so time to continue building (well after my holiday anyway)

My most recent progress has been on the wiring. There has been a lot of doing, undoing and redoing, but nearly there.

I am sticking with the glass fuses until I have the engine running. Once the basics are done I will focus on reliability.

I also assembled my shocks. They look like new. I am really happy but I am not keen on the shiny look, so I have a few ideas in store to do a total blackout on the front end.

But for now, they just look great!

 

[spyug]

Excellent progress so far.

Not much progress lately, life has been getting in the way a bit and a few hiccups with the build have been a bit demotivational

this is all part and parcel of this resto/mod game.

I've done 5 or 6 in the last 8 years and the first one took over 18 months but the last only 5 or 6. Frame offs are going to take the longest as there is so much to do and if you are anal, like my good buddy and fellow conspirator Gatekeeper, it could take a lot longer. Attention to detail can get you tied up but by far the biggest time waster is waiting for parts or suppliers to find the parts.

This game can be a bit manic depressive. There are highs when everything is sailing along and lows when waiting for things or dealing with issues like broken or stuck fittings, electrical gremlins or my personal favourite"self inflicted lack of oil pressure" (long story detailed in the archives). Eventually it all works out and gets soon forgotten when she rolls out in all her splendour, running like a Swiss watch and you're getting ooohs and aaahs from all the possers.

I think the key is to pace yourself. Take some time off now and again and when hitting a snag walk away for a day or two. If you go at it hammer and tong (as many of us do) you will wear yourself (and family) out and the project may just die.

When it stops being fun and starts to feel like a chore its time to quit. Don't let it get like that. You now have too many new friends dying to see how it turns out.

cheers man,
spyug