79 Special Cafe Custom Build Progress

[jrobertfox]

Anyone have a tank?

You're doing some really nice work, I can't wait to see it finished.

Thanks! Appreciate the kind words.

Body guy from Classic Powder came by today to pick up the frame and a box of parts, plus the tank and fender.

Looks like I might be better off buying a replacement tank than fixing up the old one. Anyone have one without the emblems (like they were never there at all)?

Finished up most of the painting of the various "difficult to powder coat parts" all that is left are the calipers and lower tripple tree.

Of course here are a few pictures:





Both are flat, the above is just wet...

So pumped to get the frame back and start putting this beast together!

[natemoen]

The only tanks that never had the emblem mounts was the 81H. Those are like hens teeth and you will pay plenty for a good one.

Best bet is to just fill the holes. If powder coating best bet is to use Lab Metal to fill the holes, also not terribly cheap though.

[crazy steve]

Even Lab Metal isn't all that great at filling for powdercoating. It doesn't have the same expansion rate as the parent metal and you'll see the 'seams' around the filled part if you have to put much on. Thin or small areas it's ok, otherwise not so good.... BTDT... Best results will come from 'pre-baking' it before you apply powder.

And while I love powdercoat, I personally wouldn't recommend it for bodywork. While powder is chip and most liquid-proof, it does scratch rather easily (much more so than paint), picking up 'micro-scratches' from any cleaning. The only cure is to apply a 2-part clear paint over it, which rather defeats the purpose....

[jrobertfox]

Is that the light at the end of the tunnel?

Been a while, but got parts back from powder today, and they look awesome, started some light assembly and finished painting a few odds and ends. Still waiting on the tank and fender. And the seat, grips, battery belt are also still in progress.

This should start to look like a bike again soon.

[Eveready1100]

Just curious, mate. How tall are you?
Wondering what sort of cafe-ish bars you are planning on using that will work with the stock footpeg locations. You might end up getting your elbows resting on your knees.

[jrobertfox]

I have clip ons attached to the shock tubes which are pushed up through the top clamp a little, as in this picture:



Also started final assembly and got the engine in with no trouble at all!


Simply took off the oil filter and valve cover, layed engine on side over a wool blanket, over newspaper and bricks. Slid the frame on and bolted it in. It was awesome. Then just righted the little lady.



Should have more pics soon of the sweet new pegs.

[DGXSER]

That is an interesting blue color for a frame.

Nice progress! Obviously lowering the front end a bit with the forks poking through like that. Are you dropping the rear as well?

[jrobertfox]

Some more pics

Things are coming together. The dark blue on the fender looks great. I needed to get the stripes redone on the tank.

[dondons1984]

Well Solidworks is very advanced software... but managed to hack out a custom header concept:



I'm not sure if it makes sense to measure everything and model stuff, or fit the exhaust pipe/ collector and then slowly fit the primary pipes. I'm not wildly into some of the 4-1 headers i have seen.

my exhaust is what you are trying to build.

[jrobertfox]

my exhaust is what you are trying to build.

did you do it custom, i need to post a pick of that exhaust on the bike, it looks great.

[cpmaynard1980]

wow what a nice looking build!

[WMarshy]

Have you thought about making an X pipe? If I the had the tools and welding skill I would build an X pipe similar to the Campbell x-pipe except make it a 4-2-2. Cylinders 1&2 and 3&4 Y together then go into an X crossover under the motor near the oil pan then dual exit right behind the foot pegs on both sides...

Here is the Campbell X-pipe...
http://www.x-pipe.com/motorcycle.html

[dondons1984]

I don't know if the pipes are custom. I'll post pictures of it later. It almost has a street racer look to it.

[skids]

Here is the Campbell X-pipe...
http://www.x-pipe.com/motorcycle.html

No access to the oil filter!

[dondons1984]

yeah to even get to my filter I have to remove the exhaust. that is a downfall.