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77 Cafe Project

Discussion in 'The Garage' started by glaswerks, Mar 25, 2013.

  1. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor


    Here are a couple direct links to the Tarozzi high-rise clip-ons:
    Dime City Cycles
    Fast From the Past

    Maybe you can find them cheaper with a bit of search time.
  2. sbaugz

    sbaugz XS650 Addict

    Yep those are the ones I was referring to.
  3. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Those look really nice and beefy. I will try the current ones and if they dont end up being keepers I will try the Tarozzi bars.
  4. sbaugz

    sbaugz XS650 Addict

    They are nice
    I have the standard no rise tarozzi bars and they are awesome
  5. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

  6. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    I bought a cheap set like that one (not that one) some time ago. I'm here to tell you, when a hammer head breaks in two, and part of it hits you in the face, you'll be forever cured from using cheap hammers.:mad: It's one of those things you just don't forget.
  7. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Sounds like the 2x4 and hammer are in order..
  8. Square Circle

    Square Circle XS650 Addict

    Nice mock up. Do your clip ons touch the tank sides at all? I have a set also, but havent tried them out yet. I am using the exact same tank on my build and also needed to hammer in the underside of tank for frame clearance.. the metal is pretty soft and pliable under there.. i just used a hammer to do it and took my time, it worked.
    The triple clamp looks great btw.
  9. sbaugz

    sbaugz XS650 Addict

    I have the same tank using tarozzi clip ons and they do not touch tank
  10. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Thanks, the clips dont hit the tank right now, but the Headlight clamps are close. I am sure that problem will go away when I "gently" pursuade the tank bottom and move the rear mount.

    The Tarzolli look really nice. I really like the look of the XS750 tank and seat combination.

    Have to cut the frame section tomorrow, can't find my sawsall blades. :). Oh well lost a night...
  11. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Well made some more progress yesterday.

    Finished installing my air distribution for my compressor so I was able to use my pneumatic air tools. Of course I spent about 2 hours finding and fixing leaks.

    So progress

    Rear frame loop cut off
    Old brackets for seat and side covers cut off

    Started the grinding, lots more work here.

    Working on the details for the rear loop. Anyone know the proper tube sizing that is required? I am think 7/8" tube is correct. But looking for input.

    Not sure how I am going to bend the tubing :). Really don't want to have to buy a tubing bender for a one time use.
    Mailman likes this.
  12. 5twins

    5twins XS650 Guru Top Contributor

    Can't you re-work the loop you cut off? It's already mostly bent for you.
  13. willyguzzi53

    willyguzzi53 XS650 Addict

    I cut mine off, shortened it, reshaped just a little and welded it back on.
  14. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    The problem with the original loop is that it was a little (about 2 inches) to short to fit the seat I purchased. Looking around the internet for ideas for bending the tubing.

    Own a lot of tools, but a tubing bender is not of them. I am going to source the tubing from McMasters (love that place). 2 pieces, 7/8" and 5/8" for inserts.

    I am planning on integrating the License plate holder to the loop as well as the turn indicator brackets.
  15. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Ok well after pondering the loop issue for a few days, spending a couple of hours are Harbor Freight looking for tubing benders and pricing the materials I realized it was cheaper to get a preformed unit.

    Ended up purchasing a pre-bent loop from the guys at Dime City :).

    Plans for this weekend

    Fitting the Radian Swingarm
    Modifying the swingarm bits to work with the CB750 axle I picked off of ebay.
    Finish up pounding the tank tunnel to fit and mount
    Finishing the mods to my motorcycle lift.
  16. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Well a little more work on the project over the past few days.

    Received the Dime City loop, looks very nice, had to tweak it slightly to fit.

    Removed old swingarm and fitted the Radian unit. very nice!!. Of course, now I need more tools. A 51/64 bit to modify the chain adjusters and open up any necessary spacers.

    I wanted to cut the passender peg mounts off, but reviewing the bike I find the brake return spring and brake light switch are mounted to right mount. I need to fit the rearsets and see what kind of solution I can come up with for the new problem :).

    I will post more pictures this weekend.

    Additional equipment purchased to support this project :

    Oxy / Acet welder (used)
    Vise and pedestal (used/new)
    Silver and Deming bit
    Heating Nozzle for welder .
    Last edited: Apr 18, 2013
  17. 5twins

    5twins XS650 Guru Top Contributor

    Nice of you to think about the brake light switch mount and return spring. Most just lop the parts off then end up walking around with their thumb up their ass later, lol.

    You're doing a fine, well thought out build. Frankly, most on here are real hack jobs.
  18. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    Well I didn't realize there was going to be an issue until I removed the swingarm. Thing I spotted the return spring and said "oh sh$t" :).

    I think I have a solution for the brake light switch. A normally open micro switch that contacts the lever behind the HUGE gusset. That way when the pedal is depressed the switch closes the contacts. I will have to survey whats available at Mouser Electronics.

    I could also use the micro switch that Jaguar used on the XJS throttle pedestal, worked much the same. NIce Jag part, about $45.00 yikes.

    Now where to relocated that dame spring :).
  19. 5twins

    5twins XS650 Guru Top Contributor

    You may have to add a bent piece of 1/4" rod to the frame if you decide to remove the loop, ala the XS1. See post #4 here .....


    We just couldn't seem to get through to the German in that thread, probably because of the language barrier. He probably still doesn't realize he cut the mount off, lol.
  20. glaswerks

    glaswerks XS650 Newbie (Still a newbie)

    That is one way to do it, I would really like the "hide" the spring. But that is quick and simple :). Another thought I had was a "compression" spring that loads up when you press the brake and unloads when you release brake.

    I need to take a few pictures of the current mechanism and throw it on my computer in Solidworks and see what I can make it do..... I mean it is a "project" bike :)

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