The BOSS - Cafe racer build

[JvZ]

Thanks Spyug, I keep telling myself that it is a learning curve. I think that the best bit is painting. The transformation that a coat of paint gives is just so satisfying. I have decided to focus on the exhaust next. Although it is a long way off fitting I think it is going to be a satisfying little project. Well, either that or getting the tank dents removed. The latter will at least mean it will look like a bike again.

[JvZ]

Ever wanted to see the inside of a Motad silencer?



Thanks to Wally, there is no way that exhaust was going back on!

[Agemax]

why not???? a bit of header wrap and it will be good to go. would look really cool as well with header wrap and loads of garden twine holding it all together......

[wally]

Sorry...

That looks similar to what my Buells exhaust looked like (until I modded it! )

This was the stock exhaust:


Gutted with new per pipes and elbows:


Repacked and painted:


Fitted:


And I replaced the cheap wrap with better quality ones.

[JvZ]

Wally, that looks great, i especially like the twin outlet. the best thing you can do to a Harley/beull motor is let it breathe. i have a stage 1 on my sportster 1200, with V&H pipes, it sounds and runs brilliantly. What motor do you haven your buell, it doesn't look like an evo to me?

Agemax, the pipe was fine, apart from some slight pitting and a few dings, nothing that some paint and wrap couldn't fix, but the Motad was just too ugly to go back on. And, in keeping with good environmentalism, I will be recycling the old pipe trying to make something a bit more suited to a cafe bike. I'm not going to get a chance to work on it for a couple of weeks, but watch this space!

[wally]

It is the 1203 Thunderstorm.

From what I understand it is EVO derived, but has been changed quite a bit.

Some info.

[JvZ]

Interesting reading.

Thanks for the info Wally.

I must confess as backward as the HD evo is, I absolutely love my sportster! Really hoping that this GS is going to find a similar place in my heart. I am getting a bit "gatvol" of all sorts of commitments getting in the way of getting a solid weekend to spend on it.

[JvZ]

Although in fairness I can't complain about the latest distraction, I have been spending the past week on an island in the Maldives. I head back to London tomorrow and hope to get the tank sorted. I bought some high performance coils while relaxing on the beach (gotta love eBay). That means that I can finally (albeit temporarily) fit the tank and seat to get the positioning correct. I'll get some pics up once it starts to look like a bike again.

[wally]

Lucky!

I am going to enjoy a day of riding on Saturday - while we have the last bit of decent weather!

I look forward to seeing some progress on your build!

[JvZ]

I spent most of the day yesterday cleaning my engine, I really want to get a coat or two of paint on it and get it back in the frame. I know it has an underlying gearbox issue which I'll get to in the future, so at that point i'll have to take it all apart again and then do a full rebuild, but for now I just want to get the exhaust, wiring etc all finished up and I can't bear the thought of putting an ugly lump into a freshly refurb end chassis. Also, there is a slim chance that I won't even have to strip the motor at all . A quick question to the experienced among you though, can I just remove the cam chain tensioner, paint and replace, or it that likely to upset my valve timings. I know that it is just a tensioner but I don't want to risk derailing the cam chain.

[JvZ]

I spent the day today building an engine jig out of some old gym stands someone was throwing away (the recycler in me). But damn that is one heavy engine. I have been lugging it all over the place on my own but manhandling it into the jig was just a little too much for my novice welding. Better luck next weekend I hope.

[spyug]

Again....pace yourself. Sometimes (many times) you will hit a snag and it will baffle you. I always find that is the time to take a break. Let the problem germinate in your noggin and eventually the solution will slap you between the eyes and you'll be off again. Copious amounts of mind altering drugs or booze usually help.

Seriously, it does help to back off once in a while. Relax and smell the flowers now spring is here. It will all work out in its given time.

Cheers and where are the pics, haven't seen much in awhile.

spyug

[JvZ]

Progress

Sorry for the lack of pics recently, I have a lot of half jobs completed so nothing really to share until now ( 3 day weekend in England)

I gave the engine a thorough clean over a few weekends


And gave it a coat of paint,


I used a self-etching, high-heat paint, I still have to flip it over and do the bottom and at least 2 more coats, I am using this as the primer on the gearbox/ crank casings, these will end up in an anthracite colour. I must admit though I am loving the flat black look.




The screws will be replaced by ss cap screws.

I also mounted the headlight, although I am not sure it is sitting right, I made a bracket that fits just above the ignition switch, this may have to move to below the ignitinn (will require a bit of modification so will cross that bridge when I get to it)




Last weekend I mounted the rear sets, I needed to make some spacers, poor planning meant that I ran into some clearance issues between the master cylinder and the swing arm



I think they look great though.


Snug but at least it is all clear.

I can't wait to get the engine in and fill the gaping void in the middle of my frame.



That's all for this week,

[JvZ]

Thanks Spybug, I thought that I needed to get some little things done to feel like it was moving on some. Was hoping to get some riding done this weekend. Well got a little of that done, took a ride out to a Harley dealership and my bloody sportster died in the parking lot and I had to get my wife to fetch me. So bottom line, less riding, more building. I generally find tinkering in the garage very relaxing, so it really works for me.

[spyug]

took a ride out to a Harley dealership and my bloody sportster died in the parking lot and I had to get my wife to fetch me.

Too funny! You didn't just make that up to entertain us did you?

Stick with the GS and you won't have those issues

I'm liking the all black theme......very sinister.

Keep up the good work.