Dean's XJ650 Cafe Project

Xulf13,

Man, every time I call him he says "check back in two weeks!" Which is funny...... I haven't been looking at the phone bill but my wife gives me "the look" every time I say I'm about call him again! Anyway, last time I called him he said he had actually finished the pan to the tank and to... guess what? "check back in two weeks!" So that's progress anyway. It's only been 12 months so I guess I shouldn't be too anxious, right? :lol:

Thanks for the tip about the bracket. Hopefully this project will move along much quicker now.

Dean

 

Dean,
Please tell me you did not pay them up front. I have had bad experiences when I pay upfront. I once had a body guy restore my Monte carlo...well...3 years later, the car only had primer and all the money was spent and the rest is history. I do hope you get your tank and don't go thru what I went thru.

Hence the reason I learned to wrench on my own and do the work whenever I can. Of course building a manx tank is more complex. I just can't wait to see it.

 

Xulf13,
No worries, I haven't paid them yet. In fact, I was actually kind of impressed because last fall I did something sort of stupid, I offered to pay for it. He refused to take any money though. He said he wouldn't do that until that was done and I had seen it and was satisfied with it. So that's cool. It's just taking forever! It's killing me!!

Dean

 

Ok, today's update. I've been working on upholstering the seat. I've never done that before and I'm not sure I like the way it's coming out, but we'll see how it looks when I get done.

First, the bolts get epoxied down on the seat pan.



Then the foam was glued on and the cover is getting glued on top.



Finally got my new rear rim put on. This turned out to be a challenge. First of all, I got the rims from a 1986 Yamaha Virago XV700SS. After I tried to install the rear, I realized that the brake shoe plate is specific to the Virago, so I had to order that, as well as the brake shoes, springs, and actuating post. That went on ok, but the assembled rim would not fit in the swingarm like the original rim. I ended up having to take the axle gear case off the back of the drive shaft, put the assembled wheel onto the gear spindle, then put the gear case back on the shaft. Then I figured out that the axle is model specific, too, so I had to get that part! In the end, though, it's all together and looks awesome! The tire is a 15" instead of the original 16" so I'm wondering how that will affect performance. I'm guessing that the acceleration will improve but my top speed and gas mileage will go down. I also pulled the muffler back off and spray painted the mounting bracket and bolts black. Much nicer, I think.



So there it is. Inching towards completion.

Dean

 

The outside diameter of the tire will determine the effect on your mileage, top speed and acceleration, not the wheel size. Actually, it will be the rolling difference of a full revolution of the tire when loaded, but the percentage change in outside diameter will be close enough.


Bike is coming along nice, and those tanks are incredible! Really want to see it when you finally get it- those things are works of art! I see the site says they need to have the bike on site for custom tanks- are they able to work around that for others, or did you have to talk them into it?

 

that rim is awesome

 

I know- I answered half asleep last night just so I could find the thread and reread it when I decided to go with spokes on my own Seca.

 

I took the old tank and cut the bottom off of it and mailed it to him. So, supposedly, it's going to drop right on if he ever finishes it. I've been waiting about 18 months now and the last time I called, he basically said, "don't call me, I'll call you." So I'm pretty stuck and am considering another tank for the time being...although I'm afraid it might be the permanent tank. I really don't understand. I spoke to him in June and he told me he had about two more hours worth of work. Here it is September and I'm still waiting. It sucks 'cause I'd really like to have that tank but I don't know what else to do. Fortunately I haven't paid him anything but it cost me about $50 to mail the tank pan to him. Oh well.

 

Man, that's too bad. I had a bad feeling about it from the get go. And I don't even know the guy. But at least you just lost $50. Who knows maybe he'll finish it some day. But I wouldn't hold my breath if I was you. Try elsewere, there are other company ( IN THE Good US of A) that will work with you for that kind of money.

Are you done with the seat yet?

 

you would think with the way the economy is he would finish up that project to get paid, anyway hope you get a really nice tank soon. Project looks great.

 

I have a couple questions on this.


What parts did you use from the Virago, after all was said and done? And did you have to modify anything? I really like the idea of using spoked wheels on my Seca, and I found a rolling '86 700 Virago for cheap, so I would love to do this swap, even if I need to lace a different rim onto the rear hub.

Do you have any pics of the whole bike with both wheels on it? And did the front wheel fit fine, including the rotors?

Any more info on this swap would be greatly appreciated.

 

^^WHAT HE SAID!!^^

ANd I did mine's LOL. Works like Bob's Your Uncle, too..

 

Had to get the new rim, brake shoe plate (the outer, chromed plate on the right hand side looking forward), the brake shoes, springs, actuator post, and the axle. Nothing had to be modified but I had to remove the rear gear housing from the drive shaft, mount the wheel, then reinstall the gear housing.

Haven't done the front wheel yet. It's built for dual discs and I'm afraid to see what other pieces I need to get that to work right!! It's coming up soon, though, on the list of things to do.

 

Spoke to the Tank Shop yesterday. He told me he was working on the tank "as we speak" and that he would call me in a couple of days when it's done. We're at an easy year and a half, though, so no breathe-holding on my account....

Cut a piece of sheet metal to make the battery shelf. I don't know how to weld so I used pop rivets to attach it to the frame.



Also got the headlight buttoned back up. I installed a headlight modulator, which only added to the incredible amount of crap behind the headlight! I finally did get it all smashed back in there and screwed down. Almost looks like a motorcycle again!



My first stab at putting the upholstery on the seat failed miserably so I'm redoing that. Hopefully this time will go better....

 

cool, glad to see you're still around and kicking, I remember, this was teh first thread I viewed when I came to this site.... Damn you!


just messin... does the bike run?

 

Er...the battery hasn't been on the bike since I started this. Plus, I've got the carbs off and in pieces! I'm doing a rebuild and a jet job on them. I bought some cool looking pod filters. I know, I know...many will say that the pods are a bigger pain than they are worth, but I'm going for the "look" and for that, in my opinion, you've got to have the pods. I mean, if I wanted the fastest thing out there, I'd be looking at a Hayabusa or a Ducati or something!

 

Joined after you had taken a "break". Just wanted to congratulate you on patience (tank), staying with it and GOOD work :wink: ...

skillet

 

awesome. this is going in my inspiration file. you dont see a lot of guys with the early xj's (80, 81) trying to cafe because the tear-drop shaped tank just doesnt look cafe. I'm super interested to see it finished.

power to ya

 

where are you at dean? we want to see your progress!

 

Stewart,

I'm really stalled out and bummed, too. The guy who is supposedly working on my tank keeps putting me off. It's been almost two years now and I still don't have the tank. And I had to cut up the original to send to him as a pattern! So I have no tank at all. Fortunately, I haven't paid him anything but, dammit! I really wanted that tank! I can't figure out if he's just not working on it or has so much work he can't finish it. Doesn't make any sense in this economy...I'm practically begging to pay him and he won't do it. I guess I've got to look for something else. I don't want a fiberglass tank, though, so I don't know what I'm going to do now.....

 

SUCKS ABOUT YOUR TANK! what a pain this guy must be!

i am really interested in your exhaust in the pics here...was that chrome originally and how did you paint it if so? also, where is it from? it's cool! i really want get the cafe look out of my bike too but while xj's are awesome bikes, they don't have really great lines for that style. too many curves and no straight lines. know anyone selling a KZ anything? lol

i cant wait to see the tank on with the rear cowl on there!

gl

 

Yeah, it was originally chrome. They were kinda cheap...got them from Dennis Kirk and they rusted very quickly. I used to have it parked outside. So I took them to a guy in town who does powder coating. I was very pleased with the way they came out.

You're right about the curves making things interesting when trying to do a cafe, but that's what you're looking at!

 

yeah i guess...if they engine wasn't so awesome i'd have traded up long ago but they're built like tanks and quick to boot. be sure to keep us all up to date!

 

excited to watch this one hopefully its happenin soon for ya

 

Cool bars big guy, are those clubman bars? think'in about a set of those myself

 

If you get a set of clubmans don't get those kind, the pinch on them tends to make them weak and they WILL eventually break. It happened to me.


Get these kind instead. Nice welds, no pinched tubing = strong/tough.



Dean, don't get discouraged, just get another tank and modd it to fit your bike. Look, you're wasting time, I know those type of guys. I hate to say it but I saw it coming. Get your bike together, don't let the tank stall you and keep you from doing the rest. If you're interested I have a spare Seca tank you can use, just pay the shipping. I know it will fit your bike.

Then, go to ebay and look for cafe tanks. Every once in a while you will see a daytona alloy tank for sell for around $450 or so. all you have to do is mark where you want the tabs placed for the rubber mounts and take it to a local welder (you may have to take the bike too) can't cost you more than $80 for the job and you're good to go.
You can also check for alloy tanks like this BSA tank.
http://cgi.ebay.com/ebaymotors/BSA-Vict ... 4aa01f8736

Or check this other link. It's quite a bit of money, but you were going to spend about the same with the other guy and you waited too long man.
http://cgi.ebay.com/ebaymotors/ws/eBayI ... &viewitem=

Let me know if you want my spare tank.

 

Yeah those bars look better yet, plus the mirrors are a cool on the ends of the bars like that, how'd you obtain those?

 

Get these kind instead. Nice welds, no pinched tubing = strong/tough.

What brand is that? Where did you get them? I got the other kind, but I'd rather replace them if they're just going to break on me.

Dean

 

^^^^^^ some on ebaymotors from the looks of it.

http://motors.shop.ebay.com/i.html?_nkw ... ars&_rdc=1

 

Ok, here's an update. Got the carbs back on. I actually broke down and just bought a new rack (so if anyone's interested in the original rack, let me know). I put in a jet kit for the pods and then put them back on the bike. I know there are those who are very against the pods but I think they look awesome!

 

Looking real good Dean, Any news on the Tank yet? I always come back and check on your build, then disappear, lol.

Been working on mine too, but i now have 4 bikes and it's hard to keep up with build threads. When you get it running PM me with results please.

 

Oh and sorry, But yes I bought my clubmans from ebay $28 shipped. and the bar end mirrors are Napolean. Kind of expensive but wrth it, the cheap replicas shake and vibrate like crazy. I used to have the cheap ones so that's how I know. Instead of wasting $30 on cheap bar end mirrors spend $75 or so and get the real deal.

 

Hey, xulf13!

Yes, I'm being pulled between different projects, too. I need to get those heavier bars...I bought the cheaper ones not really thinking about ti. Where did you get the billet clamp?

The tank is supposedly done. He left a message on my phone a little while back but I haven't called him yet. THREE YEARS AGO when I first called him i had the money set aside for the tank. As the YEARS have gone by that money got siphoned, so I'm waiting on my income tax refund. Hopefully, though, I'll be posting some awesome pictures soon!

Thanks for checking in!
Dean

 

I'm may be just ignorant but I was looking for that Chrome fork clamp? how do you order that?

 

You may have some luck checking out MikesXS under handlebars. Not sure if it's a direct fit though, you'll need to make sure.

 

ddibling, what jets are I running now?
Lot nice then Emgo pods, eh?

 

ddibling, what jets are I running now?
Lot nice then Emgo pods, eh?

 

Just a tip for reducing bar vibration, go to your local gun dealer and buy a bag of bird shot. Put some kind of a plug in one end and silicone it so it seals, after it dries tip the bar on end and fill it with bird shot and plug and seal that end. I have weighted bar ends on my bike so I didn't have to plug and seal. The only thing you need to watch for is if the bars have factory holes for the switch locating nubs as this will allow the shot to run out (ask me). The added weight of the shot acts as a damper and absorbs excess vibration. May help with the mirror issue and reduce the tingling on longer rides.

 

I did this about1 and 1/2 years ago with my clubmans. it works, but not on the cheap mirrors, the cheap mirrors are just plain crap.

HEy Dean, do you at least have photos of the finished tank? I can't wait to see it. hey if you can't afford it, let me know and I will buy it in your place, lol.

 

Any updates on this build???

 

watching this!

 

What happend to this?

 

Any updates on this project? Been following this for ah while now. Updates please!!!

 

BUMP!

 

Sorry, fellas, this project is officially dead. I was busy working on my doctorate and now I'm busy getting divorced and, you guessed it, she got everything, including my bike! I'm lucky to be escaping with my balls! Anyway, looks like I'm back to square one...

Dean

 

what kind of world is this?!? sorry to hear that. take care.

 

Call me my uncle Vinny can help with situations like this

 

Sorry to hear brother. hope you can get back on two wheels soon!

 

Terrible to hear, keep your head up

 

wow after reading this whole thread and it ends like this! Its bad enough how bad us Men get screwed on divorces as it is but to lose you bike too... what the hell does she need that for?