My XJ 550 glass cafe

First, a paper and cardboard mockup



Then build a plug from wood/plaster/foam/epoxy/paper/paint. It needs to be a PERFECT model of the seat pan I am molding. I am planning lots of space inside for wiring, and possibly the battery.



The topside of the plug is shaping up. Only a few more coats of filler to go.
The idea was to tip the tank up at the back, and blend the seat pan in with the underside curve. The seat padding will cover the mounting flange at the rear of the tank.

 

The underside, final will be self locating and held on by only the tank bolt.

 

looking good, i am guessing you have done this before

 

Nice work, I like the way this is shaping up!

 

Never done it before.
There is a TON of info and how to's on the net.
I have done some truly miserable body work before. Maybe that was practice.

I skipped a lot of early attempts. My first plan was to build the thing in wood and ply and then skin it with thin aluminum. As it went along I decided to try a cardboard model. That was a blessing. I found a way to use the original teardrop tank. I think it's going to look nice. I'm thinking red powdercoat frame and details and white tank and tail with check stripe down the center.
Still thinking about the bars, It might work with the British BSA "home market" bars, if not I think clip ons. I'd rather not use cafe bars, just a personal preference.
The clipons make a project for me, figuring out what to do with the stock risers. They are cast right into the tripletree. Maybe a mount for gauges.

 

maybe you should clear up "self-locating" 'cause one front mount on a seat sounds NUTS!!!

 

Nice work,indeed! How hard was it to make the rear frame loop? It looks great!

 

Seat looks cool!

Looking forward to the end result.

 

The back of the underside clips under the fender crossmember/bracket. The front of the underside holds a perf-metal box with all the electrics. The box wedges between the frame sides and crossmember. One bolt will do fine.
I worried for a week over just how to make that loop. Finally I grabbed a piece of HEAVY thick wall galvanized pipe I yanked out of the wall when I was doing some kitchen renos, and started bending it by hand in the vise. I just left the jaws open a bit and threw my considerable weight into it. Bit by bit I nudged it along. There are some divots but I can grind them out. I need to clean it off for brazing anyway. It makes a great handle for shifting the machine around. I'm going to make sure I leave finger clearance at the back so it stays useful.

 

Hey Ease.
I love your bike me son.

I spent a lot of time looking at how you put it together. Thanks for the inspiration.

 

Thanks!

'me son'? Hmm... You're not a Newf are you?

 

Bluenoser

 

Pretty close then. hah. :wink:

 

Aren't we all Newfs deep down?

 

for your first try you are doing an amazing job. Looks like you built a really nice (and sturdy) plug that you can pop lots of parts from. You should make a mold for later use.

 

I have a lot of patience. I really love fixing machines up to look like new. This machine however... well, let's say the look was dated, and not in a way I like.
It's taking a lot of styling cues from my BSA. Maybe it's something I secretly desired for the Beezer, but could not bring myself to do to it.
I suspect I will take the time to make a really nice job of it, and I will make a production mold. You never know, I might sell a few.

The woodwork underneath that sealer looked really nice with all the layers of the plywood showing.

 

Pictures say so much more than words.
I would caution you, I don't have much use for foam as a molding compound, everything melts it, it is too flimsy.
If I started again, I would use all plywood and short strand fiberglass reinforced polyester filler.

 

The plug is done.
I'm waiting for my son to deliver resin and gelcoat.
Meanwhile, I'm going to tackle cleaning and polishing the engine, and stripping the frame.

 

Oh, you might notice a section of fender on the back wheel.
I was thinking I would make the rear fender a floating fender attached to the swingarm. Then I'll have a place for my taillights and number plate.

 

engine porn