RobbieRobot Cafe Racer Project in pictures

A sneak peek but I'm not sure I want to keep the tank.

 

Time to figure out the wiring.

 

New switches being sorted.

 

New heat shrink tubing on the right switch assy.

 

Then the left switch assy.

 

Switch gear all working correctly.

 

Carbs back on and she runs. Still need to do a full strip and glass blasting of the carbs though, with new tube seals etc.

 

New fuse box.

 

Left brake caliper re-assembled with new seals, Brembo pads and Goodridge SS braided hoses.

 

Re-con Darmah tank arrives so I try it for size.

 

Note the mock-up battery tray. It's a baking tray I nicked from the long-suffering missus.

 

Don't worry. The tank will eventually be re-sprayed.

 

Mods to make it fit.

 

Right hand caliper fitted and brakes bled (with some difficulty).

 

Stainless steel mudguard gets the chop.

 

Full movement check. Plenty of clearance.

 

That tank looks sweeeeet!!!

 

The tank does look nice on the XJ. Too bad that it didn't come with the rest of the Dharma though; those were sweet bikes in their own right.

 

It is only right that this thread gets my first post. This build is awesome.

 

Thanks for all the feedback. I've been too busy working on the bike since March but last night I thought I'd make the effort to share it, especially as I've used this site for loads of technical assistance. There is still some way to go so I'll continue searching for the wise words of the experts notably RickCoMatic and Bigfitz52. Thanks guys. Meanwhile we're having a heatwave in the good old North East of England so I may be easing off a little on the hours.

 

Really Nice build, and that tank is awesome!
But you really need to make a new bracket for the dials (unless your going for fairing as well?)

 

Are you going to "correct the lines" of the seat pan now that the tank is fitted? (it doesn't look like you can simply lower it)
That IS a nice looking tank !

 

Looking good so far. Love the tank. I see you went with pegs moved back. flipped shifter seems to do the trick. What are you doing on the brake side to account for the move?

 

Cheers broberg. I'm not planning on fitting a fairing. I have an instrument bracket from a CB750 which I'll be trying out towards the end of the build but I quite like the high clocks. Nothing is set in stone yet, cosmetically.

 

Cheers
That photo was taken 5 minutes after I took the tank out of the box. It's not fitted yet, just propped on foam blocks. I will be looking at finalizing the cosmetics once the battery and electrics are repositioned and secured.

 

Cheers Steber. Yes, so far so good.
I may be looking at fitting rear-sets at some point in the future but as it stands those are stock pegs re-fitted in the original position. Remember it's a UK SPEC bike.

 

Not happy with the mounting bracket I previously welded on the tank so removed it.
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Welded some new attachment brackets onto the tank.
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Attachment brackets.
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Now to prepare the tank.
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Tank rubbed down.

 

Improvised method of cleaning the inside of the tank. (Video)

http://s1360.photobucket.com/user/Robbi ... 6.mp4.html

 

Hi, what kind of rear fender is that? Im looking for spmething like that but without any succes...

 

Hi rozko,
The rear mudguard was bought from eBay. Here is the link;
http://www.ebay.co.uk/itm/5-Universal-r ... 3a818eb264

 

Thanks RobbieRobot!

 

I really like the look of the tank! can't wait till u have finish with the bike!

kinen

 

Thanks kinen1. I hope to be getting back to putting the hours in soon having spent most of August touring and walking in the Lake District, The Yorkshire Dales and the Scottish Borders with the wife and our dog Mollie while the wife was on school holidays.

 

Front mudguard stays being fabricated.

 

Front mudguard fitted.

 

Mudguards fitted

 

Carbs dismantled

 

Carbs soda blasted.

 

Electrics tidied up a bit.

 

Mounting plate for electrics.

 

Battery mounted.

 

Carbs ready for reassembly.

 

Extreme cleanliness is a must.

 

Throttle shafts re-fitted with new seals.