RobbieRobot Cafe Racer Project in pictures

Seat painted and lacquered.

 

Cardboard template for forming the dash warning light bracket.

 

Preparing to cut out the aluminium sheet using the template to mark it out.

 

Cutting out the instrument warning light bracket.

 

Roughed out instrument warning light bracket.

 

Instrument warning light bracket drilled and polished.

 

LED warning lights being fitted and wiring soldered to terminals.

 

Heat shrink tubing covering the soldered wires.

 

Connecting up the wiring inside the head light. Notice the new bar-end mirrors.

 

Instrument warning light bracket fitted and working.

 

This is really making me want to redo my brakelight bracket. I used steel, not the much-lighter aluminum you are.

 

Tank sprayed and finished with several coats of lacquer giving it a deep lustre.

 

Still looking good though.

 

That says a lot, coming from you. Your work is impeccable.

 

Robbie,

that is a beautiful warning lights bracket mate!

kinen1

 

Wow, Loving your project! I hope to make my own brackets from Aluminium.

 

Very beautiful build sir. One question:

It looks as though you mounted the SS mudguards using aluminium brackets. If this is the case, are you worried at all about galvanic corrosion occurring?

In my trade, we often use non-conductive spacers/sleeves/washers when this may cause issue so I'm always a bit paranoid about it.

~Rev.

 

The paint's looking bootiful

 

Love that aluminum panel for the dash lights! Also what bike did your master cylinder and clutch perch come off of?

 

Thanks Kinen 1. How are things progressing at your end?

 

Thanks BikePike.

 

Thanks for the complimentary feedback and thanks for alerting me to the possible problems with galvanic corrosion between the dissimilar metals. As I understand it, stainless fasteners in aluminium don't pose too much of a risk, however I will now revisit the assembly method and fit non-conductive washers where possible. I believe things are less likely to corrode when kept dry. Do you know how quickly the corrosive effect will take place if left unchecked?

 

Thanks Andyam6, I am pleased how it's turned out especially as I've only used rattle cans. I actually got the tank on and connected up yesterday and had a few test runs up and down my street. So far so good.

 

Thanks colehole. The master cylinder and front brake assembly with adjustable lever came off a FireBlade. I had a bit of amazing good luck when I bought the master cylinder. I bought it off eBay from the photo but it didn't say which bike it was from. It came without a lever and to my amazement a spare lever that I happened to have from my previously owned beloved FireBlade fitted perfectly. The clutch lever assembly which is also adjustable, is from a Kawasaki ZX7R if memory serves. Almost all of the stuff I've fitted was obtained through eBay.

 

I'm not really an expert on the subject but I'd imagine in a salt-free environment, it would be quite a slow process. If your area uses salt on roads or you live near the sea, I'd be a bit more concerned.

If it's not a giant hassle to install some insulating spacers, it certainly won't hurt. If not, just keep and eye out for white corrosion in the aluminium bits.

 

And a little anti-seize compound. It helps it insulate the metals from having direct contact as well, and it makes taking it back off in 20 years a lot easier. As my father-in-law likes to say: its not for you, its for the next sonuvabitch who has to take it off.

 

Yes, very good addendum! In a pinch, even just a little grease on the threads will go a long way.

 

Most of the aluminium brackets that I've made are only semi-polished with the intention of going back to do a more thorough job once she's all together in an initial assembled form. You can spend too long on the detail and take forever to get nowhere if you are too fussy. Once I'm happy with the overall configuration I will return to the detail and improve it. That's when I can address the issue of galvanic corrosion. I live about six miles from the coast but the roads where I live are salted from around November through to March, however I won't be using the bike on a day to day basis. Fortunately I can pick and choose when I ride her. Great feedback though thanks guys.

 

I like your father in law, he is definitely a forward thinker.

CN

 

Test Ride

 

I love your work and I love the warning light set up. I was thinking of doing something similar. Where did you get those lights?

Thanks

 

Hi lhicks. The lights can be found here http://www.ebay.co.uk/itm/261021225148? ... 1439.l2649

Thanks for your kind words. Keep us posted with your progress.

 

ID plate

 

Starting to look like a Cafe Racer

 

Brand new Motad 4 into 1 (Below) replaces old one (Above)

 

Ha, now that's f'in sweet.

 

New exhaust now fitted

 

New Motad 4 into 1 from rear

 

More pics of the new exhaust

 

Shiny Silencer

 

Closer shot of collector box

 

Just needs new handlebar grips to finish off this bit.

 

Right handlebar

 

Left handlebar

 

Front view

 

Still needs seat pad

 

Rider's eye view

 

Thats one very sharp setup. Be proud.

 

I'm very impressed with the detail you are putting into your build. It looks awesome!

Where did you source the control switches? I need to get ones like you used so I can get more tank clearance at full lock with my bars.

Tony

 

Thanks Groundhangers, that's very kind of you.