xj600 cafe fighter (pre diversion)

been a while since i've posted anything....had new baby girl, moved house several times and just haven't had time.

the old thread is:
http://xjbikes.com/Forums/viewtopic/p=2 ... tml#236753

But i've changed direction since starting again so thought i'd make new thread.
Yes i know another cafe build but its the aesthetics of the cafe that i'm after. the overall style and idea of a simplified light weight bike with improved handling, also fighter influences..

I appologise for the pictures only got my phone and not the best quality.

Stripped down to bare frame.


Cut out the battery tray and brackets on the subframe that will not be reused. Also cut the subframe tubes and raised the rear by roughly 100mm.




Cut the rear section off the seat foam....not changing tanks so will be using the standard seat foam due to shape of tank.

 

Re: xj600 cafe fighter

Going to fibreglass my own seat hump which will have battery and electrics under.
bought some florists oasis foam and glued the blocks together.


Cut out the basic shape....



And with seat foam to give idea of scale...


Added a couple of scallops to the seat so it would reflect shape of the tank rather than just a plain hump.


Then just started sanding out a shape that i liked.....came out something like this......

 

Re: xj600 cafe fighter

Looked into changing the rear shock, but no matter what shock or linkages i tried nothing fitted...measured swingarm pivot and did some research on alternative swing arms so i could get a better /modern tyre fitment.



Up came a bandit front and rearend at a very reasonable price.


even came with a couple of clocks..so that will save some leg work. Will change the bars and fibreglass a new front guard. think clubmans may be too extreme so maybe just some straightish drag bars.


The rearend fitted in quite easily without too much messing.




So this is trial fitment.


Thought i might be able to have under seat exhaust but think that was unrealistic not enough room really. So raised the subframe by another smidgeon and that is as far as i have got so far. Now i know the final subframe angle i can get it welded up and jump on with fibreglassing the seat unit and seat pan.



Will need to sort some rearsets and get mountings for these done at same time as subframe.

 

Re: xj600 cafe fighter

sweet build mate!

 

its gunna look good when its done ,, need to get them rearsets before we weld that frame up ,, just incase need to manufacture a bracket,

 

wow so far so good, looking forward to the end result.

 

Will the rear sprog line up or will you need to play with offseting?

 

Going to have to play with offsetting i think but will be 530 pitch chainset, there's a company here in the u.k i've ordered chainsets from before and they can work out teeth ratio and such like.

 

Coming along nicely. Gixxer - unfortunately "Grinder" belongs to another Norfolk XJ'er!!!

 

Sorry but picture heavy.......

Pinched inspiration for exhaust from col Scottish cafe racer... :?



Wanted to try a direct mount shock so the mock up began.

 

Once happy the shock mount was dooo able.

 

Put engine back in to check suspension sag and stance...






Sorry bout the crappy pic


Bandit front guard was cut up and turned round so now have a little front


and the left over should do a hugger

 

Good to see another cafe racer XJ being progressed. Starting to really look the part now matie69, your doing a good job on it.
The exhaust looks sweet :wink:

Keep it going.

Cheers
Col.

 

Looks great! Can't wait to see it done.

 

I like the look of the bike - especially the drops.

Do I spy a Cibie headlight? (The best headlight I ever had on a bike)

 

Can't believe I missed this! Fantastic stuff, keep it up!

 

definetly a very cool build!!!!

 

Any up dates on the bike? I would love to see some new pictures and how you put the seat and rear together. For I am doing a cafe racer build my self and could use all the help I can get.

 

Seat foam is being covered at the moment so will be jumping on with fibre glassing the hump and mounting electrics very soon..

Been sorting the rear brake, the bandit caliper is under slung with torque arm but using that would be too easy and i think it looks a bit cluttered.
so been trying to adapt the xj caliper to fit.







Enlarged the pivot hole to 22mm on the slider and mounted it to the bandit swinger. Have drawn up an adapter plate that i'm waiting for a mate to cast so the caliper will cover swept area of disc.





Think it looks quite discreet and means i can still buy over the counter servicables.

 

Question what would I need to do to get my 1983 Maxim 650 gas tank leveled so it can have that cafe look? Anyone

 

Not been on here for a while but time for a catch up.......so be prepared for lots of pics.

This is the first time i've attempted this size project before and certainly not done any spraying before. As i'm on a budget of nearly nothing i have got to use what i can afford so rattle cans are used.

After stripping back down the prep work began.

Frontend:
The paint was removed using Nitromors and then wet and dried. Etch primed and normal grey after that.



U-pol gloss black was then used on forks and wheel and some clear coat sprayed after.





The yolks were also treated to a nice coat of satin black.



And this is what it all looks like.....





Overall i was well chuffed with my first attempt at painting.

 

Started on some of the engine cases as well,...just a bit of tidying up. Used wet and dry from 180 to 1500 grit and a good old dose of elbow grease, sat on my kitchen floor in the evenings while misses watching soaps. :lol: :lol:

When happy with polishing repainted with black gloss and finally clear coated so i don't have to be polishing constantly.

I know its not mirror finish but its enough to add detail to the engine which is due to be treated to a coat of Satin black so these bits should just set it off.

 

Frame:

Stripped the frame of paint and good wet and dry. Then smoothed the frame rails and plates.



Etch primer was sprayed first then normal grey primer, made it easy to see any further filling required.



Sooooo all ready for top coat...........

Chose Ford mars red.....my camera phone is pretty crap and just cant get the true colour or heavy pearl in the paint to show in pics so included an example.



Paint shop advised a 50-50 mix so after getting everything ready off we go....



That was last night so not had time to check if all is well yet....also need to clear coat, but i will post more pics in daylight once i've finished.

 

this is a awsome build

 

Been to check the frame today under sunlight and its alot more vivid than i imagined......it really does stand out....in a good way, it has a more bronze tinge to it and the gold flecks and pearl just cant be seen from what i've posted.

But this has bought me problems in that the paint i was gonna use for tank and seat just wont work.

sooooooooooooooooooo.......

Been researching some old skool Yam paint jobs for some inspiration and have found a proper little gem..



think it will bring back that old skool to the bike and certainly the gold will suit...Change the Yamaha for the classic tuning fork decal and use a more speed block pattern like pic below...(without lettering)



and i think thats hit the nail on the head...

What do you guys think, am i barking up the wrong tree????

 

I think on your cafe the block pattern would be the right choice. Any other style and I'd say it probably wouldn't work.

Just my opinion but I'm not sure if the gold would be the color I would go with, your frame might out-shine the tins...but I'm not sure what color I would recommend other than the gold.

I've seen the red on a jacked-up golf cart (redneck country here) and it does shine quite nicely in the sunlight.

Project is coming along nicely.

 

Go for the classic RD250/400 block pattern!!

 

looking good man!! I appreciate the work you put into the engine cases!!

As myself, who is stuck in the cold of winter, what covers can i take off to polish that wont end up leaking large ammounts of fluids or will need a super expensive gasket set to put back together?

Thanks and keep up the great work!!!!!

 

Managed to get better pic of the paint........ 8)



Just got to run over with 2000grit and some finishing compound.

 

Great color! I think you made a wise choice :wink:

 

Ran over with 2000grit paper but would like to give everything another clear coat, would make me feel better. Ran out as luck would have it at end of last coat, not had time to pick any up yet.

Been splitting bike into sections so planning on frontend ,rearend cleaning up any brackets and fixings that need to go on. Such as.........



Rear shock has already been repainted and i bought some Ford olympic blue for the rear spring....not decided on bodywork colours yet..but hopefully will fit in.

Sprocket carrier being prepped for a black coat.

Swingarm caps looked ace cleaned up against the swingarm so will be polished.

And front discs been cleaned and checked over.

Getting there slowly but at least its progress.

 

This is awesome... what a great bike to begin the project. The monoshock really adds to the appeal.

What size rear wheel/tire are you running? I always wondered if a 130 or 140 would fit in the stock swingarm.

Keep it going!

 

I have a 160 section tyre fitted but it is a Bandit 600 wheel and swingarm.

An fz600 rear wheel is a common swap and i believe they are fitted with a 130 standard so i would say yes quite easily.

 

Bit more work done....

The rear shock was cleaned up and a coat of Gloss Black, the spring prepped and some Ford Olympic Blue, hopefuly the colour will fit in nicely with the frame.





The sprocket carrier and assorted rearset parts were prepped,etched and gloss blacked.





Nearly finished with all the odds and sods so i can start bolting back together, tyres getting fitted this week so hoping to have a rolling frame by end of month.

 

Wonder if the early fz600 or fz700/750 swinging arm and rear wheel would interchange with the XJ/FJ 600 (gen I - pre diversion). Hum, now you have me thinking.

 

Outstanding... Love your work

 

Found a local bearing manufacturer that can supply me some new tapered head bearings at a very reasonable £7.00 each (and taper) most bike shops wanted £18ish each so quite a saving.

Got tyres being fitted on friday....do have some rim protectors but don't trust myself not to chip the shit out of them.lol sooo will leave it to the professionals.

Also been thinking about the lights and bars...undecided whether to go for a set of flat drag bars or go with ace cafe ish bars.

And the light unit thought a bucket like the MZs or BMs that have the speedo in the bowl,mmmm.

 

New head stock bearings arrived so the build up continues......

Had to have 8mm machined off the shoulder on the stem so the top bearing would seat fully but apart from that it went together quite easily.....

 

Collected a load more bits from a mates so i could continue.......

Can't remember last time i saw the tank.....



Swingarm was next in...the xj end caps fitted the bandit swinger and looked nice cleaned up.....



Pair of tyres fitted to rims so i could move it round garage...they are well past their best and will be replaced.....



The rear shock was fitted.....



And after cleaning up adjusters and end caps the rear wheel was slotted in.....



So this is how the old girl sits now......





At last it feels like i'm getting somewhere.....turned out better than i thought it would when i first started so thats a bonus.

Will have a go at cleaning engine up and servicing the brakes next.

 

Managed to get some better pics today...shows the colour much better...

 

Got more done last night.

Rearsets:





Nothing flash, just a set from an old Fz600 but better than huge lumps of pig iron that Yam gave it.

Bars:



Tried another set of bars, but turned round and upside down????eh.... do suit it quite well but would need a larger backward angle on the ends.........But i don't think i like the bandit top yokes, the risers seem far too tall so i think i'm right that GSX(katana) or Sv top yokes will fit and go with clipons.

Headlight:



Already got a dished 7inch cibie that will fit nicely.

Body work:





Dug this back out, I've made a rough fibreglass copy and am going to try and modify it to suit.
Gonna add a rounded top nothing huge just a slight radius, cut the front 4 inch or so off just to the point where it fits over frame rails, trim some of the depth so it shows off the rails and finally fibreglass a seat pan that will include the front of the tank.
Thought i'd give it a try i do like it and it reflects the shape of the tank from above......we shall see.

 

Good on yer mate ... nice n tasty work.

 

Vauxhall Astra? It looks like it is coming together well. Keep it up!

 

:lol: well spotted young man.

Didn't like the bandit top yoke, the risers sit too high for my liking so caught a couple of bargains on fleabay, hopefully should be here today.

will post pics later.......

 

want to fit a wider tyre to my xj600,so a bandit swingarm and wheel inc sprocket and disc will fit ok?

 

Try sending matie a pm. It looks like it will but you will have to rework the rear suspension to.

 

what did you do with the shaft drive, id like to switch to a chain with mine is it difficult?

 

the xj600 pre diversion came as a chain drive dude,not a shaft.

 

Could you shed some light on the front end swap! Looks very nice and a great way to add better perfor ance to the bike i reckon!