1983 XV500 Cafe Racer

Never heard of the nitric acid trick. I've drilled out the stud, even using cobalt drill bits it took ages and the inevitable happened, the drilling was perfectly centred, then went off a bit, so have a tiny amount of the threads left on one side, pain in the butt to get out.

As for the frame alignment, I went old school, no jig, but plenty of measuring!
 
In my case the stud broke just 2mm below the rim. No hopes of welding a nut or anything. Special drills were very expensive and the risk that it breaks in the process is very high. So I went another way - a reverse drill bit, but that must have been my bad day because it broke as I was trying to unscrew the stud. I found the nitric acid trick on a forum for farmers, they use it to extract broken studs, bolts etc. It's super cheap - 10 USD gets you home :D
 
I'll see if I can get some here in the UK, not always that easy getting chemicals. I did try the welding the nut on trick, never failed before, but I guess there is a first time for everything.
 
Managed to source a 17inch rim for the rear, got it for £25 including postage, then scored another bonus by getting a complete front rim, tyre etc for £42. Both off evilbay, but cheaper than new. However I have now sourced brand new 17inch alloy rims in 3", 3.5" or 4.25" for £60 and they come in a variety of colours. So will probably get a new rim for the rear, as the Cagiva rim is too narrow for my liking, I did consider swapping the front and rear rims over, but I would still need a full set of new spokes for each, so probably going to go for a new rear.

Seems like I now will have a spare 17" x 2.15" and Cagiva hub for another project.
 

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Not a lot doing this weekend. Managed to clean up the swingarm.

I think I'm going to remove the top brace and replace it with a brace on the underside. The reason being I can then mount a vertical shock rather than the horizontal one I was thinking of sticking with, albeit to the side rather like the Kawa ER6.
 

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Managed to start on the swing arm brace, only tac welded at the moment, I'm going to brace it as well.


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Managed to find some time to get in the garage today, finished welding up the swing arm brace and removed the ugly original brace/shock mount. Welding was going ok until my mask broke, nearly blinding me, then I had to use a crappy old hand held mask. The result my welds are not as good as I'd like but ok.
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I managed to find some precious time to get into the garage and finish welding the headstock to the frame.
 

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Thanks for the support.

I'm not sure on how to model the subframe yet, I'm open to any suggestions.
 
GoCrazy said:
Please don't go the "triangle bobber seat" way :) it looks like a farming machine
Click to expand...

Absolutely, I think it needs a full length seat. When I started the project I had designs of a café racer, with that style of seat, however as it's progressing, albeit slowly, I am actually thinking more tracker style.
 
Managed to find some more time today, I should of been doing some research for work, but I find making stuff much more appealing.

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I've decided to make a saddle to brace the backbone of the frame where I've welded the front engine mount to it.

I've found that finding a 2mm wall tube with internal diameter of 50mm is impossible, so I had to purchase 60mm tube with a 5mm wall. However 5mm is a rough guide, as the internal diameter is 51mm. Anyway, I've turned the tube down to a 3mm wall. Just got to cut in half lengthwise and weld onto the frame.

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Moved things on a bit, cut the tube in half to make the saddle to reinforce the frame at the headstock.
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