XJ650 Cafe Racer Project

[KevTM]

DesCB600F was kindly giving away an XJ650 (in bits) - It seems the perfect base to start with for a good cafe racer project (something i've been wanting to do for a while) - So thanks again Des, appreciate it

All the boxes and stuff took up the remaining space in my shed (not good lol).

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_1.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_2.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_3.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_4.jpg

I Nitromors'd the frame yesterday and started sandblasting it today (salvaged the sand from the speaker stands i was going to use as a fuel tank on the Bandit project/thread )

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_5.jpg

Will finish that tomorrow if the weather holds up.

I want to get the frame/swingarm/wheels/etc and the engine done fairly quickly, giving me a rolling chassis (with engine) to get some much needed space back in the shed.

[KevTM]

Spent ages sandblasting the rest of the frame, 99% back to metal.

Primed
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_6.jpg

Painted & Lacquered. (was going to powdercoat but thought i'd do the best i could do with hat i have, that way it's all done with my own hands.)
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_7.jpg

Will leave it a few days and polish it up, get a nice smooth shine on it.

Need to tackle the engine next. Any ideas on how to clean it up? Was thinking just blocking off all the ports, putting the casings back on and giving it a sandblast on a low pressure.. don't have glass beads or enough aluminium oxide.

[ms51ves3]

You could put the casings back on and block the ports up like you said, but use this.

So if any does go into your engine, you can throw a little bit of petrol in and it will dissolve it

[KevTM]

Aye good thinking. I gave it a wee go with the sand and got 90% of the crap off the fins. Gave the rest a degrease and seems ok, still needs a wee clean but I shoved it in the frame.

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_8.jpg

Started on the swingarm

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_9.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_10.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_11.jpg

Wheels next.. oh joy.

[KevTM]

Well i've been too busy trying to get the Bandit running sweet, still a wee bit rough above 8k but anyway!

Polished up the fork legs a little tonight

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_12.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_13.jpg

Went about getting the race off the bottom yoke:

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_14.jpg

Polished up the top yoke a bit, new bearings etc and wanged it on.

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_15.jpg

Will finish the forks tomorrow and stick them on. If i get time I'll put the shaft in and the swingarm.. then onto the wheels.

[ms51ves3]

Liking the forks

[KevTM]

Not finished yet, that was just a 15 minute job on each leg.. there's some scores and gouges that I don't think i'll be able to do much about.. The wee tricky bits need done, too. Polishing, don't have the patience for it.

[Munday]

Great job you have done so far.

Can I ask how you polished up the fork legs? I have two rear shocks and a yoke I need to polish up but am not getting very good results.

Thanks

[KevTM]

I just wire brushed/wet & dried all the crap off including what was left of the lacquer, basically just to get it back down to the metal and fairly smooth. Then i just used the polishing kit. The kit consists of three wheels and three compounds (as you can see in the photo) - I don't know much about polishing so can't tell you much there, I just worked my way from the 'hardest' down to the 'softest' spending 5 minutes with each.

[KevTM]

Got the forks on today:

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_16.jpg

Then set about the front wheel, some stages of the process:

Before:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_17.jpg

Paint:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_18.jpg

Polished:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_19.jpg

Whacked it on the bike, beginning to look like one now too

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_20.jpg

[Andy.B]

Looking good Got to ask as im spraying some of the bits on my bike. What paint are you using for the gloss black? Is it 2k or just celuose?
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First bike: NSR 125 (Now being restored)

CBT 28/3/08

[KevTM]

Nah just that Plasti-Kote stuff.. can scratch quite easily so I just whack on as many coats as I can be bothered. Once it's all done I'll more than likely strip it down again and get bits powdercoated. Just getting an idea on how it will look at the moment and to guage what's missing/needing replaced etc.

[Andy.B]

Ahh right, I have used 2k on the frame and since i had to scratch some off to get to the fame number i found it was as tough as old boots.

Didnt know if i should use it again on my other parts or just boggo Celuose.
____________________
First bike: NSR 125 (Now being restored)

CBT 28/3/08

[KevTM]

I've never even looked into the 2K stuff, isn't it a bit dodgy to work with? If it's as tough as you say it is I might go check it out.

[Andy.B]

Not that bad really, just use a well ventilated area and use a carbon filtered mask. Mix 2:1 ratio thats colour first then hardener then thin down if needed with thinners.

Im only using 2k for the frame and other metal parts, when it comes to the fairings im using 1k primer, 1k base and 2k laquer. Should prove to be a hard wearing finish overall.
____________________
First bike: NSR 125 (Now being restored)

CBT 28/3/08

[tutton]

2k is dodgy to work with
The isocyanates will absorb through eyes and the skin, and wont nessasarily give you lung issues now but could well do in 30 years time..
Its the hardener thats the worst for it, best way to go about it is using extraction and a positive pressure air fed mask, and white spraying overalls and gloves.

Nice job on the finish with cans so far, i thought the plastikote was only for Plastic?
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Past: '05 Peugeot XPS '99 Aprillia RS125 '94 FZR600R
Current: '02 ZX636 A1P '51 CCM R30

[element]

[Andy.B]

[tutton]

[MarJay]

I was thinking 'great project' until I saw this:

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_17.jpg

Where I almost choked.

Then I saw this:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_18.jpg

And shouted "NOOOOOOOOOOOOOOOOOOOOOO!" at my computer screen. You've just PAINTED a wheel thats worth loads of money!

That is the same as an RD350LC front wheel which is as rare as a hens tooth that was buried when the dinosaurs were made extinct! And you plastikoted it!

If you'd have got it shotblasted, polished, masked and powdercoated you could have sold it to an LC owner for loads of dosh. The key thing is that it is a twin disc wheel which only came on the 350 model rather than the more common 250.

Never mind, you lives and learns.

Actually LC owners are generally pretty tight, and the cost of getting it stripped and re finished would probably not be covered by the sale price, but I did really shout nooooo! at my computer screen as I've just spent loads of cash restoring a pre-shotblasted wheel.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[KevTM]

Managed to get a bit more done recently.

Shocks on:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_22.jpg

Bars painted, headlight on but the brackets need a tweak, not quite straight. Will end up with clip-ons anyway so they're just on to make it easier to move etc. (why paint them? lol)
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_23.jpg

Carbs were utterly manky inside & out.

Before: (you cant see the dead spiders & insects in the pics lol)
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_24.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_25.jpg

After:
https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_26.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_27.jpg

Next I will get all the bits and bobs on the engine in prep to get the bugger started to make sure it runs before I go any further.

[KevTM]

Straightened up the headlight and made a wee bracket to hold the speedo. Not going to use the rev counter or the warning light cluster. The chrome back to the speedo was buggered so I used the one from the rev counter and had to cut a wee bit out the side for the trip screw. Warning lights, well, I'll make up a wee bracket with LED's, something very minimal and hardly noticeable.

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_28.jpg

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_29.jpg

Got a bench in the shed today so it's making life so much easier

https://img.photobucket.com/albums/v407/Project_Sapphire/shed_bench2.jpg

[nightshaddow]

looking good m8 cant wait to see her finished
____________________
"WHAT DO YOU MEAN 100 MPH THATS IMPOSSIBLE Its chinese OFFICER."
Current rides CB 125 TDE(the next project) NS125RK ( now on the road ) CB125TDC (soon to be project 17) melody ( the nephews )

[KevTM]

Not done too much recently but I decided to sort out the front brake and components. Bit manky but generally in good nick.

The blobby stuff in the tub is the brake fluid! some of it sort of jellified .. the master cylinder was solid because of that but i cleared it out ok and working a treat again

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_30.jpg

Was in two minds whether to paint the calipers black or not, the deciding factor was that I don't have any plack paint (apart from hammerite smooth) so started polishing them up.

https://img.photobucket.com/albums/v407/Project_Sapphire/xj650_cafrace_31.jpg

Ideally still needs a bit more work on it. I've only got 80 grit sandpaper, then it shoots up to 600 & 800 grit.. really need 160 & 320 or something so a bit limited in the shamoothness stages.

[TUG]

Its hard to read and wank as well as scroll at the same time, i hope it comes out as i've envisioned .
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Haz ER-5, innit!