Café Commando build thread

[Jeandr]

My gas valves in place and also the sender unit for the gas gauge in the Acewell speedo / tach

Polished some parts. At first I could not get a good shine, so I tried a chrome polishing paste I had on hand. I started to do it by hand, but being lazy, I figured I could get a better finish with my polishing wheel, the results speak for themselves.

Jean

 

[pelican]

those clip ons rule!

 

[Jeandr]

Made new brackets for the front fender because the fiberglass ones just did not look good, also now I can take off the fender by removing the two allen head screws on each side and the brake anchor nuts, this is much easier than trying to undo bolts from inside the fender.

Jean

 

[Jeandr]

This should help me make good progress

I gave the parts to be painted a 20 foot paint job in white. When I bring everything to the painter, it will most likely be done in red.

Jean

 

[Jeandr]

Starting to put it together

Still a while until I have a running bike, but it looks like I will be done before the rallye except for the paint job.

Jean

 

[speirmoor]

Beautiful work Jean.
Whats the tube running from one fork to the other for?

 

[Jeandr]

Beautiful work Jean.
Whats the tube running from one fork to the other for?

The forks are from a 1982 Kawasaki KZ550, they have a spring and air assist, the tube is to equalise the pressure in both legs.

Jean

 

[speirmoor]

Mmm interesting.Cant wait to see it finished but enjoying the step by step build up and pix

 

[Jeandr]

More assembly done...

I placed the Podtronics rectifier/regulator under the seat, alternator and clutch in place. Still lots to do, but it is being done :wink:

I found a problem with the exhaust pushrods, for some reason, they are too long, I had to back the adjusters all the way for the valves to close, so Iguess I will have to take of the head to see what is going on :cry:

Jean

 

[Jeandr]

When there are a lot of wires hanging off the bike, it means it is getting closer to completion

The valves are adjusted, I had to take off the head and put it back on, the exhaust pusrods must have been riding on the edge, but now they are OK.

Jean

 

[swooshdave]

Can.
Not.
Wait.

...to see this completed.

 

[Jeandr]

This is my anti-wet-sumping valve. It took me forever to come up with something that is easy to reach and practical. I had two of those valves, this one which I planned on testing the machining on and another with a serrated pex type connector more suitable for ruber tubing. I drilled this one and tapped the two holes for 6-32 screws, everything went well. The other valve was not made the same way and I drilled inside the chamber so I will use the one in the pictures with suitable fittings.

Fear not predictors of doom, I will add a switch to let the bike start only when the valve is open, but not right now. The wiring will be in place however, no need to do something twice.

Jean

 

[Jeandr]

Even if it was sunny and warm, I worked on my bike instead of going for a bicycle ride, time is getting short and I still have lots of work to get it going. Most of the mechanical works is done, I still have to finish the plumbing of the oil lines, fill all cavities with the proper fluids and do the wiring. I will add a set of blinkers on the back even if my original plan was not to put them on because qhe Oberon bar end flashers are very bright and visible from the front and the back but I am not sure if the inspection station tech will see it that way and I don't have the time to go twice.

This is a view without the bodywork

Back view

Left side view

Pilot's view

20 foot paint job doesn't look too bad in pictures :wink:

Jean

 

[hudson29]

I have been enjoying your build as it goes along. You have the most elegant approach to switching the shift & brake sides that I have ever seen, MUCH better than what the factory came up with. Perhaps they had other considerations I do not understand, but if they had done it along the lines you show here, many of us would have thought much more highly of the later models.

Vintage Paul

 

[swooshdave]

20 foot paint job doesn't look too bad in pictures :wink:

Jean

Needs a smaller seat to compliment the rest of the bike. You could almost put a small flat track style tank and seat.

 

[grandpaul]

Ah, yes, "the sum of the parts"...

Looking good. Maybe a fiberglass cowl to cover the bum stop?

 

[lynxnsu]

Hi Jean
Have you put it on scales yet (weight?)
It is coming out nicely ,needless to say i like that empty look

ps to make it more resposive you could move those carbs backwards a bit , there is enough space there

 

[lukeya]

Jean,

JRC sell a cable choke kit for the PWK carbs - its $45 only!! Rather easier than fiddling with the buttons under the bike.,

regards

Luke

 

[Jeandr]

Jean,

JRC sell a cable choke kit for the PWK carbs - its $45 only!! Rather easier than fiddling with the buttons under the bike.,

regards

Luke

Thanks, I will look into it, but the front end seems rather "busy" right now. I am presently working on the electrics and there are a lot of wires going into the headlight shell (the two front flashers, the speedo, the two control switches and the main harness)

I haven't weighed it yet and I really don't know where to get it done either, but if possible I will have it weighed, I am curious too :mrgreen:

Jean

 

[andrew hester]

You should get the Maney Race exhaust http://www.stevemaney.com/products.html