72 cafe project

[shawn00sa]

Ten months ago I brought home the 72. I bought it from the original owner who hadn't ridden it since 73.. The motor was seized, the tank was rusty as heck, the brake fluid was powder along with it being just plain rusty and dusty.

I took it to work and began the process of cleaning it up. I had always wanted a cafe racer. The problem was this bike seemed too nice to not just leave stock. All the guys at work urged me just clean it up, get it running and ride it. (I happen to work at a motorcycle manufacturer and most the guys there are into all kinds of bikes. We make 50 and 65cc motocross bikes. Cobra motorcycles if anyone is interested. This will give me access to equipment and knowledge that should be helpful in the future. I will try and post some picks of what we do there if anyone is interested).......... So I got it running, brakes working and somewhat road worthy. The tank was so rusty the top is paper thin. It actually leaks and you can push it in about 3/4" just by hand.

I end up riding the bike all summer and planning on just riding it again this year. The problem was I got on this forum and started seeing the wonderful rides and got the bug. I really blame jdizon and kott motorcycles. I loved their work. I ride the bike to work on Saturday and started tearing it down Sunday. In the mean time I have started ordering parts. Here is what she looks like today. Hopefully I can lean on you guts for some guidance.

The shopping cart is parts I am not planning on using. If you see something you need let me know. The flat cart is stuff I will or might re-use. My plan is 4-5 weeks to have her up and running.

 

[Kathos]

Its tough cutting up a nice bike. I try to keep the nice ones stock and modify the dirty ones. Only so many of these bikes floating around now adays.

 

[yellowdog]

Hi from the uk ,would you be willing to send the tank badges to the uk ?

 

[shawn00sa]

They are not in the best shape. But I would be glad to help you if you need them.

 

[shawn00sa]

Today's project....polishing. So frustrated I can't find a tank. Hopefully my rear sets and bars come in tomorrow. I would love to be able to mock it up this weekend and see what it would look like.

 

[CalsXS2]

Today's project....polishing. So frustrated I can't find a tank. Hopefully my rear sets and bars come in tomorrow. I would love to be able to mock it up this weekend and see what it would look like.

What was your process for polishing.

 

[69mach351]

The polishing work looks very good. I would be interested in knowing it too. I am guessing it was pretty time consuming?

 

[shawn00sa]

About 2 hours on a buffing wheel. I am new to it. Just a wheel we have at work and we have white compound. I will post a pic of the set-up later today.

Thanks!

 

[DanW]

Since your forks are off -- shave the 2 fender mounts at the bottom of each fork if you're not using them for a cleaner look

 

[shawn00sa]

Since your forks are off -- shave the 2 fender mounts at the bottom of each fork if you're not using them for a cleaner look

I think I am going to try this tomorrow. How about the upper mount on the right side?

 

[DanW]

They all come off fairly easy. If you want pics let me know

 

[shawn00sa]

Sorry....

 

[yellowdog]

Pm sent regards parts thanks

 

[shawn00sa]

I took your recommendations and shaved off the fender mounts. It was much easier than I expected. Overall I am happy with the look.

Here was my process. Started with black polishing compound and just went to town on the buffing wheel in the picture below. I would switch to brown compound occasionally and see what it looked like. There were a few spots where I removed larger defects or blended areas such as casting marks with green scotch pads in a grinder. When I got close to what I wanted I used white compound. I just kept switching back and forth until I was happy. I have about 6 hours into these forks.

Now I started working on the frame. The parts I removed weighed 5.6 lbs. I bet with the grinding it is closer to 7-8lbs. Tank will be here tomorrow. I hope to be mocking up some stuff then. Fingers crossed. I just sprayed some black paint on it temporary. It will be powder coated when I am done.

 

[shawn00sa]

Got my tank today and mounted it. Rear sets are fitted. Bolted on Ohiln shocks. Testing a few different seat options. Wish my clip-ons were here and I could see what it looked like a little better.

 

[Shorty]

How much you want for the old tank? Just picked up a 72 myself

 

[shawn00sa]

My old tank is junk. The top is so thin it has split. Still interested?

 

[shawn00sa]

Machined an aluminum brake rod tonight. Old oxidized stamped steel on the left, new one on the right. Just needs some polishing.

 

[shawn00sa]

Made some progress on an aluminum seat pan today. Remounted my tank as I wasn't happy with it. Hoping to get some things buttoned up this weekend and maybe powder coat next week. What am I missing before powder coat?

 

[shawn00sa]

Any advice for stuff I need to finish up before I paint this? It's my first build and can use some advice here.