79 XS650 Hipster Killer Cafe

vonhofej

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First off I'd like to say thanks to all the posters who contribute here, without you guys there would be no way this bike would have turned out like this on the first try.

I've been working on this one since 2010 and its about 95% complete. I got the donor bike from a trailer park in Delaware for $400.

Features and Modifications:
-277 rephase
-Rear wheel conversion kit
-Brembo brakes
-WM3/4 Spoke wheels
-750 big bore kit
-xs750 gas tank, sanded to 600 grit w/ clear powder coat
-Radian swing arm
-Progressive rear springs
-RaceTech gold emulators
-Tarazzo rearsets
-Sparx PMA w/ giant green coils
-X-Arc duo signals
-A bunch of other stuff, a bag of chips and heck of a mechanical journey for a novice

Photos:
1. Donor bike
2. Engine replacement parts
3. Cleaning up the frame (note turnbuckles as new exhaust mounts, trying to keep the hardware store in business)
4. First mock-up with the motor back from powdercoat (not pictured - lack of money in back pocket)
5. Motor & exhaust reinstalled with checker board exhaust tape
6. Begin rebuild of seat and tail with all new electrics
 

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So one of the parts of this build that turned out well was matching the pattern on both brake rotors. I upgraded the front rotor to the Brembo (BCEN20-1010 from 650 Central) and put a 19" wheel conversion kit from (Omars) on the back. I ended up with a super blingy front end while the rear just faded into the scenery, I decided to match the pattern and clean up the center of the stock rotor on the rear.

Tools and Material: cardboard, awl, drill press, drill bit, ruler, template material (metal & wood), jig saw or band saw, screw driver.

Steps:
1. Place the Brembo bling on a piece of cardboard (picture 1)
2. Push bolt through the cardboard to stabilize rotor (picture 1)
3. Trace the center hole and use the awl to mark the original pattern (picture 1)
4. Remove the Brembo rotor
5. Mark the center and draw lines radially outward through middle of the punched holes (picture 2)
6. Put the old rotor on the bolts so it matches the center index from the Brembo (picture 3)
7. Draw a line to indicate the outside radius (picture 3)
8. Find the offset between the radius of both rotors, in this case 2cm (picture 4)
9. Mark the location of the new holes toward the center using the standard offset (picture 4)
10. Punch new holes on the marks (red line pattern, picture 5)
11. Cut out the cardboard pattern and transfer it to a piece of template material (picture 5)
12. Cut a block of wood to match the radius of the stock rotor (picture 6)
12.
 

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13. Line up the block of wood and the outside radius of the original rotor (pic 1)
14. Drill holes with drill press (picture 6)
15. Fasten the block of wood to the metal with a piece of mounting tape (pic 6)
16. Draw holes around the rotor, overlapping the first and last hole in the template (pic 2)
17. See if it lines up where the patterns overlap (pic 2, the two circles indicate I'm off)
18. Drink heavily and go to bed
19. Take the space between the mis-match and divide by the number of patterns (pic 2)
20. In order to adjust the pattern that distance move the block of wood to change the radius, in this case it was moved toward the center of the rotor to make the pattern tighter (not pictured)
21. Repeat step 18
22. Once the pattern is laid out, match the holes around the rotor and drill (pic 3)
23. Complete drilling around the rotor, the patterns should match at the end (pic 4)
24. Powdercoat or paint the center web. (pic 5)
25. Admire your way cool matching rotors!
 

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Nice work. I'm jealous. Lol. ..Colorado and a nice cafe..awesom. Whats the low down on the spokes and rims using omars front hub kit? Sizes and such? I want wire rims now.
 
I like your attention to detail. I wish I had the patience, time, skill, etc.
Well done.
 
I don't mind Hipsters, as long as they can work on their own machine...

Square Circle,

The rims are both 18" Buchanan's The front is a WM3 (2.15) x 18" SHOULDERED ALUMINUM with an Avon Roadrider 110/90-18. The rear is a WM4 (2.50) x 18" SHOULDERED ALUMINUM RIM with a 120/80-18. I'm running Omar's kit with a Radian swing arm, so I had to get a different axle and bore the holes to 20mm. I'm sure you could do it for cheaper but at the time I had no lady friend and a good paying job!
 
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