82 XS650 Cafe Racer Build

Any suggestions on a good paint removal spray or something like that? I need to get this tank down to bare metal so I can fill in the little dents and paint.

Waiting on blinkers, taillight, and headlight, and replacing the hand controls so I'm now cleaning up the wiring.
3D printed a headlight bucket. Currently sanding that and getting ready for paint.
 
I don't care for the Special side covers when you fit a nonSpecial seat. I acquired standard covers from '77 or '78, not real sure the year, and mounted them on my "81 special. You can see the look and some details here. This is from "It's time to start winter project" thread. I do like your fender treatment for your style bike.
View attachment 236306
Did you go for the original airbox or are there pod filters under there?
 
Any suggestions on a good paint removal spray or something like that? I need to get this tank down to bare metal so I can fill in the little dents and paint.

Waiting on blinkers, taillight, and headlight, and replacing the hand controls so I'm now cleaning up the wiring.
3D printed a headlight bucket. Currently sanding that and getting ready for paint.
A random orbital sander (D.A.) with 36/40 grit on the big areas, followed up with 80 grit. On the areas you cannot get to, a small air grinder set up for 3M Roloc discs using 3" or 2" 3M brown (course) conditioning discs should get most of the rest. Real tight areas will require hand scraping and a small wire brush. I recommend wiping it down with a wax and grease remover and applying epoxy primer directly to it, letting it cure then lightly scuffing the dented areas with 80 grit and then doing your fill work. When that's done, epoxy it again, then sand and use filler primer till satisfied. Today's paint strippers are pretty useless.
 
Any suggestions on a good paint removal spray or something like that? I need to get this tank down to bare metal so I can fill in the little dents and paint.

Waiting on blinkers, taillight, and headlight, and replacing the hand controls so I'm now cleaning up the wiring.
3D printed a headlight bucket. Currently sanding that and getting ready for paint.
1677515417570.png
 
Pods, currently cheap pleated KN knock-offs. It has TM34s. Uni's might go on when I get it running.
Knock off K&N pods often cover up small intake airways on the carb Body where they mount. I had genuine K&N pods (which clear the airways) on my 1980 BS34‘s and it ran well, or so I thought. Changed to unipods and hello! Bike runs much better; no fluffiness and cleaner take up on a rising throttle
 
Progress update
Headlight bucket installed with new modern style brackets.
Seat is properly mounted.
Located and fixed the oil leak but I have a feeling that these bikes just like to mark their territory...
Upgraded the front break caliper to a larger dual piston for some better stopping power.

Working the tank tonight; need to strip, prep and Bondo it so I can take it to a pro for paint.
While that is being painted I'll be working on finishing up the wiring. I ordered some simple blinkers and a single tail light to fit with the bobber style fender.

We're in the homestretch for spring.
The bike is already registered, just need to update tags and renew the insuranc
 

Attachments

  • 1.jpg
    1.jpg
    207.6 KB · Views: 110
  • 2.jpg
    2.jpg
    389.8 KB · Views: 108
  • 3.jpg
    3.jpg
    391 KB · Views: 106
Headlight looks great! What speedo are you running? I need to give my headlight and gauges some love.. I'd love to swap out my headlight but I need to figure out how I'll do the turn signals (if any - I see you omitted signals altogether?).
 
Headlight looks great! What speedo are you running? I need to give my headlight and gauges some love.. I'd love to swap out my headlight but I need to figure out how I'll do the turn signals (if any - I see you omitted signals altogether?).
So my setup is different now actually. I will get some pictures and links for you by tomorrow.

The speedo is super easy and cheap. - https://www.amazon.com/DKMOTORK-Motorcycle-Speedometer-Tachometer-Multi-function/dp/B07WW3L3Y8/ref=sr_1_3?crid=8Q2MN5312DXR&keywords=cafe+racer+speedometer&qid=1682433532&sprefix=cafe+racer+sp,aps,134&sr=8-3

I swapped to this bucket and brackets - https://www.amazon.com/dp/B09ZNW3PBR?psc=1&ref=ppx_yo2ov_dt_b_product_details
It's an all-metal construction.

Here's the blinkers - https://www.amazon.com/dp/B07GZLN7L7?psc=1&ref=ppx_yo2ov_dt_b_product_details

Here's the fitting headlight - https://www.amazon.com/dp/B07T28C69B?psc=1&ref=ppx_yo2ov_dt_b_product_details


I am the budget master
 
Thanks for the links! I'll have to see if I can find similar items in Canada. Are you running factory wiring? I recall there being a pile of wires in the headlight housing - just wondering if you were able to fit them all in the new setup or not.
 
Thanks for the links! I'll have to see if I can find similar items in Canada. Are you running factory wiring? I recall there being a pile of wires in the headlight housing - just wondering if you were able to fit them all in the new setup or not.
Mostly factory, I bought some new snap connectors and am working on swapping everything over. The bucket I sent fits all the factory wiring and then some. The headlight is significantly thinner than the factory light
 
Back
Top