DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: The Limey on Apr 02, 2016, 12:54:38

Title: FZR600 Neo-Cafe
Post by: The Limey on Apr 02, 2016, 12:54:38
As mentioned in my intro post, I've just started work on a 1991 Cafe type project.

I've had a think, and I'm pretty sure that no matter what I do it'll never look like it was made in 1960!  However, the Cafe racer ethos appeals, and I've planned a machine that's going to be true to the ideals of simplicity, light weight, minimal bodywork, racy seating position, simple styling.  I could so easily have gone the Streetfighter route, but I find the motocross-barred-erect-seat-unit-blingy-paint-in-your-face-look a bit hard on the eye (although I'm cool if you dig it!), so I'm after the simpler, more discrete, stylish look.  Imagine that 1960 had taken place in 1991 and the boys have stripped a Fizzer to it's bare essentials for night-time blasts down the Western Avenue, and you'll be in the right place.  Plans...

Performance:

Even on a bad day, its a sub 12-second, 140+ mile an hour machine.  That's absolutely ample for someone who's knocking on a bit (like me!) in a country where the fastest you can legally go is 70.  However, the engine will be checked over and rebuilt as required to ensure that it is running A1, and may be geared down a tooth.

Handling+brakes:

I'm a big chap, 6'4" and 265lbs.  I do fit on a Fizzer quite comfortably, but my mighty muscled torso (or flabby spare tyre, as my Wife so unkindly describes it) is a lot for such a middleweight.  Fortunately the previous owner as also a hunk like me and it's had a Haybusa rear shock conversion, so the featherlight Fizzer is an easy job for such a shock to manage.  Forks are in good order, so I'll refurish and look at some heavier springs.

Brakes are 4 pot calipers on the front, and seem clean and free, so I may just rebuild and repaint.  I'll keep an eye on eBlag for a set of 'blue spot' jobs, but I'm happy to re-use what I have.

Looks:

A lot of this will be determined by my wallet, as I retire from full-time work this year.  Some will be by the limitations of such a machine itself.  Nevertheless, the plan is retain the standard clip ons, bin the fairing, standard tank cover, R6 seat unit heavily modified and slimmed down to a) make it fit, and b) keep it looking subtle.  Frame, wheels, engine, as much detailing as possible in gloss black,no fairing, 7" round headlamp, single speedo and wally lamps in the tank, topped off with I think the Martini Racing livery, white with the slim red and blue stripes - contemporary to it's era, but simple and uncluttered.

So the last few days I've...

Polished the supplied silencer.  It was an easy win, and a good place to start...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0019.jpg)

Front mudgard/fender bobbed about an inch off either end, and prepped for paint.  Can't bob such things too much over here of when one goes for the MOT (annual government roadworthiness inspection) the tester gets angry and is liable to foam at the mouth and not offer you a cup of tea while you wait...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0021.jpg)

Next I broke out a can of gloss Hammerite smooth, roughly equivalent to your Rustoleum, and attacked the starter, fuel tank stay, and exhaust collector hanger...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0023.jpg)

Then did the same to some engine mount spacers, clip ons and clutch lever...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0022.jpg)

Next off it was out with the metal polish to attack the heel plates and front fork brace.  Stupidly I didn't photograph them before slipping them in a freezer bag and giving them a squirt of ZX54 ready for storage...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0020.jpg)

Today I've been stripping carbs.  I was expecting some dreadful mess, but was pleased to find the slides aren't scored, the floats are intact, diaphragms are sound, needles and emulsion tubes aren't visibly worn.  Very happy.  A good clean inside and out, reassemble, and they'll be wrpped up and added to the box labelled "Thank F*** these Bits Are Finished!"

More pics as things slowly progress.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 02, 2016, 13:07:28
This isn't the exact look I'm going for, but it's in the ballpark.  Quite nice, eh?
Title: Re: FZR600 Neo-Cafe
Post by: VonYinzer on Apr 02, 2016, 15:10:08
Just picked up a 92 FZR600. Interested to see how this comes out.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 02, 2016, 15:53:57
Thanks Von.  I'd be interested to hear about yours too.  In the UK we got a strictly limited edition version with John Kocinski paint and signature, and bundled in with the spares is a tank cover and front fender from one of those, so I may slap them on eBay to raise some pennies.

Once the carbs are clean and reassembled then my next job is to drop the swinger off the frame and extract the shock.  The damper looks in good order with no leaking, but the spring is corroded and that would never do.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 04, 2016, 06:26:16
Carbs clean and reassembled.  I did contemplate polishing the bodies, but in the end I didn't.  I have no polishing gear so it would have to be done by hand, and they're out of sight between the frame spars, so I'm happy to just know they're clean...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0024.jpg)

Rear lamp also cleaned.  I'm not sure I'll be reusing it yet as that depends on the dimensions of the final seat build, but it's now done anyway and on stand-by for deployment if required.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 06, 2016, 13:13:25
More progress today.  Done some prep on the dummy fuel tank, filling, rubbing, and a couple of layers of hi build primer.  I'll let the primer settle and cure fora couple of days and then give it another rub down and some more primer, and repeat until I'm happy with the result.

I also removed the fuel pump and filter set up and brackets.  All the mounting rubbers have been carefully cleaned and are in good order, plenty smart enough to re-use.  The pump has been stripped, inspected and the contact breaker points within cleaned up.  It's then been reassembled and the pump and bracket given  a coat of silver enamel paint.  Once the paint has cured and I've reassembled I'll post up a pic.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 06, 2016, 13:17:57
Nice work so far.

Cheers.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 07, 2016, 09:00:22
Today I finished stripping the frame.  Swing arm (swinging fork if you're being picky), shock and linkage removed.

Shock needs to go in the vice so I can undo the pre load collars and strip it down.  Unfortunately, my vice isn't yet fitted my new bench so I need to sort that out first.

I'm pleased that all the bearings are very smooth and in good order, and all have thick coating of clean looking grease.  Clearly this machine was well looked after at some point in its life.

Started rubbing down the swingarm for paint.  Taking my time, it'll be a few days before it's ready for rust treatment and priming.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 08, 2016, 05:42:21
Done some rubbing down of the swing arm ready for paint.  Some minor rust which I've rubbed down, but will treat it with Kurust prior to paint.

Rear sprocket it filthy, but unworn.  The machining marks are still visible on the sprocket teeth.  Cush drive rubbers also appear virtually new.  Whole lot cleaned up very nicely, no painting required.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 08, 2016, 13:27:12
Nice, that's like the GL Ibam stealing parts off, it's an 81 has 3500 km on the clocks, I didn't believe it until I saw the bearings and brakes and other wear parts, like new under a very thick layer of crud.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 08, 2016, 13:36:19
Thick greasy crud is good.  It looks awful and helps lower prices, but preserves the goodness underneath for those of us willing to go hunting for it. 
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 08, 2016, 15:17:29
Yep.  My buddies keep coming over as I get a new bit cleaned and mounted and they can't believe it came of the crusty parts bike. ;D
Title: Re: FZR600 Neo-Cafe
Post by: semmins on Apr 08, 2016, 15:20:36
Been looking on ebay for an FZR 600/1000 for a while, there seems some good deals to be had.
Just being a nosey bugger, where in the UK are you.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 08, 2016, 15:55:23
Rural South Northants.
Title: Re: FZR600 Neo-Cafe
Post by: semmins on Apr 08, 2016, 17:02:01
Not a million miles from me.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 13, 2016, 12:14:30
Here's a before pic of the fuel pump.  Filthier than a night with Carol Vorderman and a keg of Guinness.

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0025.jpg)

'After' pics due soon.

Here's the swigarm prepped and painted...

(http://i189.photobucket.com/albums/z79/The_Endorser/Q5CPBVCXOZ/DSCN0026.jpg)

It's been sprayed with black Hammerite.  Now, I thought long and hard about the choice of finish.  Much as I love it, powder coat was out on economic grounds.  I seriously considered enamel gloss black such as PJ1, but I've decided I don't want a facory look to components, but more of a hand-finished look.  That's not to say sloppy or nasty, as I'm going to make sure everything is meticulously painted, polished or plated etc, but I don't want the components to look like they've just plopped off the conveyor at the factory - if I wanted that I may as well buy a new bike (and I am, that'll be the 650 Burgervan I've promised myself as a retirement pressent).  I want them to look like they've been done by an an enthusiast at home, but done well, with care and effort.

Well, it's done now!
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 13, 2016, 13:05:37
I like the hammered finish, it hides flaws in the metal and is durable etc. Great for frames, swingers etc.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 13, 2016, 13:12:42
Thanks buddy - I'm liking you more and more!  ;D

I'll do the frame in hammered black as well.  It's a right royal ballache to reassemble without damaging paint, but nothing I haven't done before.  Everything else will be gloss black, except for the crank cases which I'm thinking of doing in wrinkle.

Tomorrow is time for a bit more rubbing of the tank, some more work on the rear wheel, and a tidy up of the man cave.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 13, 2016, 13:20:29
I have used 3-4 different hammered colours on bikes, Did a 450T frame and swinger in silver, My CX has a cast iron hammered paint and it looks great, best part is, you don't worry about runs or anything with the way it lays and it fixes itself. I have used both spray and brush. it is good for hangers, footpeg brackets and all that too. 
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 14, 2016, 14:49:42
And today I have been filling and wet sanding the fuel tank cover.  A bit more priming tomorrow, then a final rub, then a final prime and leave to cure for a week or two before paint to allow for any sinking or shrinking.  It's a slow, tedious, tiresome, utter ballache, but there ain't no substitute for time and patience.  Anything South of perfection just won't do.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 16, 2016, 04:10:27
Today I'll be painting the bottom yoke.  Undecided whether to paint or polish the top yoke.  I'll have to mull that over a Guinness or three.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 16, 2016, 13:49:08
Walking round the garage not paying attention and I headbutted the yoke which was hanging from the rafters.  It hurt.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 17, 2016, 11:04:37
Outch, more pints will make that feel better though.
Title: Re: FZR600 Neo-Cafe
Post by: yorkie350 on Apr 17, 2016, 11:25:38
That will show ya for not wearing ye olde bowler hat old chap  ;) nothing a guiness wont cure mate  :o
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 17, 2016, 11:59:15
Thanks guys.  Got a bump on the head  but thankfully the paint was undamaged - thats the important thing!

No real progress to report today. The Missus is out and I got the sprog.

Undeterred, I sneaks  the brake caliper indoors and checked them over.  Surprisingly clean and in good order, with smooth moving pistons and no evidence of leaks.  I thunked it over and then ordered some Rustoleum Appliance Stainless Steel spray to repaint them.  I'm quite looking forward to that.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 20, 2016, 16:11:12
Been working this week so not a great deal happening.  However, started stripping the Busa rear shock for cleaning and to repaint the spring.
Title: Re: FZR600 Neo-Cafe
Post by: Ryan Stecken on Apr 21, 2016, 08:10:06
Keep up the good stuff.any pics form the bike?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 21, 2016, 13:06:56
I'm off work again across the weekend so ill catch up with my picture taking duties.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 25, 2016, 07:28:34
Today I painted the rear caliper mount and the caliper itself.

I painted the mount in Hammerite to match the frame.  Lovely.

More interestingly I used Rustoleum stainless appliance spray on the caliper and it looks stunning.

I need to get some pictures up, but at the moment most items are still hanging up while the paint cures, and I'm just a bit wary of unnecessarily handling items whet  the paint is still green.  Soon my friends, soon...
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 25, 2016, 08:40:40
Does the stainless appliance have a heat rating?  I know calipers get hot, I am guessing the paint is OK for ovens and such so they get hot, but is it rated hot enough?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 25, 2016, 10:45:23
Good point.  Short answer is I don't know for sure.  However, hammerite survives calipers just fine, and the appliance stuff is supposed to be ok on cookers, so I'm pretty comfortable with it.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 25, 2016, 10:50:45
That's what I was thinking, ovens get pretty hot sometimes and the paint stays.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 25, 2016, 12:46:37
After much nagging from the Missus I've decided to re use the original  cover and front mud guard.  It was a rare special edition, so I guess it's nice to keep the spirit alive...

(http://i189.photobucket.com/albums/z79/The_Endorser/FZR/011.jpg)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 25, 2016, 12:48:28
I'll probably pay a pro to paint the seat unit to match.

(http://i189.photobucket.com/albums/z79/The_Endorser/FZR/012.jpg)
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 25, 2016, 13:14:08
cool.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 25, 2016, 13:14:39
could always get another tank and guard to paint and mothball the limited bits for future too.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 25, 2016, 13:50:33
I've another tank and guard already primed, so that's not a bad idea.  I'll get some quotes when I get the seat done, see how anally invaded it'll leave me.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 02, 2016, 11:16:10
OK, apologies for the lack of updates.  One of the downsides of being a carer is I don't always get the time I could like.

Things are still progressing, albeit slowly.

I've rebuilt the fuel cock with a repair kit and resprayed the fuel tank.  That is to say the real tank, which is hidden from view once the dummy cover is fitted.

A few other brackets and bits repainted, and the Goodridge brake hose fittings cleaned up and polished.

I'm now cleaning up the shock, which I now believe is a GSXR600 unit rather than the 'busa unit I'd originally thought.  The shock body was excellent, but the spring was a little tatty.  Dismantled it all, cleaned up the spring and slipped a length of electrical heat shrink label over the spring.  A few minutes with the hot air gun and it looks good as new, but won't chip like paint.  Just need to reassemble.

Progress pics soon.

I''ve decided to spray the wheels with a fine truck bedliner, more in this soon.

And then I'll be starting on the frame.  Watch this space.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 02, 2016, 14:54:40
As promised
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Sep 02, 2016, 16:36:18
I'm in.   I like your inspiration pic.   I have a 94' YZF750R that I want to get going one of these days.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 02, 2016, 17:41:22
Can't be many of those left now.  They were pretty uncommon even BITD.  Well worth reviving it.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Sep 02, 2016, 22:34:11
Can't be many of those left now.  They were pretty uncommon even BITD.  Well worth reviving it.
I hope so, I have a 1000cc Thunderace to bolt into it!

What's next on yours?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 03, 2016, 10:37:36
I think next job is the one I've been putting off because of the amount of work - the frame.

I need to modify the sub frame to accommodate the planned seat, grind off and smooth any extraneous lugs and brackets, get it prepped for paint, then paint itself.  Once that's done i'm in a position where I can slowly start bolting bits back onto it, which is always a turning point in any project.

Once I've a rolling chassis I can then easily move the bike about my slightly limited work space, and then I can begin work on the motor.  Top end rebuild at the very least I should think.
Title: Re: FZR600 Neo-Cafe
Post by: teazer on Sep 03, 2016, 21:37:56
Crazy thought and not where you are probably aiming to end up but have you thought about an M1 Rossi replica?  Tank can stay but needs a smaller race type seat to replace the heavy looking thin they came with.  That would be a modern race rep and that's the idea behind a Cafe Racer.  We sort made our old bikes look more like race bikes of the day.

Just thinking outside of the box.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 04, 2016, 04:50:43
That's not a bad idea.  Unfortunately, I'm a very large gentleman and would suffer leg clearance issues on a faired FZR600 (I've ridden a couple over the years) as they're quite compact scoots, so probably not terribly practical.  I'm a big fan of Yam sports bikes from around 1985 to 1995, and in an ideal World would love a full house of FZ600, FZR400, FZR600, FZ750, OW01, FZR1000 and an EXUP thousand, so perhaps when I eventually get the big bore Fizzer that may well be the way I go, although the lure of Kenny Roberts yellow and black speedblock colours is also strong.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Sep 04, 2016, 06:20:09
YZFs were hardly rare, I had one and can't remember it being difficult to find one, had a FZR600R as well and an R1.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 04, 2016, 15:35:37
I can only speak of my own experience of the UK, and of the OW01 era models to which I refer.That generation were never catalogue models and were only imported in batches.   Only 16 currently 'taxed' and road legal in the whole country according to the DVLA (our equivalent of your DMV).  By any sensible measure that's fairly rare.

Rather more 95 and on models, but still slim pickings compared to Gixxers and ZXR 750s. In any case, these fall outside my period of interest.
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Sep 04, 2016, 18:19:02
Going by your inspiration picture I'm looking forward to seeing how this evolves.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 05, 2016, 05:16:48
Thanks for the words of encouragement chaps, much appreciated.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 06, 2016, 14:40:10
Today I painted the rear suspension knuckle.  Did this also in Rustoleum stainless appliance enamel.  Should contrast nicely with the black shock and linkages, and the spray can of Rustoleum I bought seems to last forever...

Hung the frame from the rafters, about 2.5' from the floor, ready for final tidying, prep and painting.  That's an exciting point as once the frame is ready it's turnaround time bolting bits back on.

Then did a bit of housekeeping, tidied up the workshop to keep Mrs Limey happy, even though she never goes out there
Title: Re: FZR600 Neo-Cafe
Post by: teazer on Sep 06, 2016, 14:48:20
Does she look like Emma Peel, to match your Steed look?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 06, 2016, 14:57:11
She does indeed, Sir, but sexier ;)
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Sep 06, 2016, 16:49:37
Then did a bit of housekeeping, tidied up the workshop to keep Mrs Limey happy, even though she never goes out there

If she knows where 'there' is, she knows too much!
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Sep 06, 2016, 17:11:32
I know a man with 10 OW01s, he also has a couple of YZF750 SPs and 3 R7s.
YZF750Rs were available from most Yamaha dealers from 93 onwards, not a big seller though thanks to the Fireblade.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Sep 06, 2016, 17:20:54
I know a man with 10 OW01s, he also has a couple of YZF750 SPs and 3 R7s.
YZF750Rs were available from most Yamaha dealers from 93 onwards, not a big seller though thanks to the Fireblade.


Um, this "man" ?   He sellin?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 07, 2016, 04:41:43
If he taxed them he'd almost double the road legal examples in the UK.

Thinking about the build while laying in bed (it kinda takes over your life!)... why don't manufacturers fit grease nipples to suspension knuckles?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 07, 2016, 10:52:35
Had a few other things on today, so couldn't get up to much. Finished tidying the workshop, and hung up some shelves to give me storage for finished components awaiting refitting.

I then pained the back plates for the rear wheel adjusters.  I was going to polish them, but I got this can of Stainless Appliance Rustoleum that seems to be bottomless, so why not?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 08, 2016, 14:32:12
Today I rubber down the rear suspension dogbones.  I'm undecided whether to paint them silver or black.  In will sleep on it.

Also started cleaning up and rubbing down the frame.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Sep 08, 2016, 17:48:01

Um, this "man" ?   He sellin?
No, a couple of the OWs are ex Yamaha WSB bikes, all of the R7s have Yamaha race kits, lovely bloke, rides the OWs regularly at UK track days.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 11, 2016, 11:30:00
And after much angst and deliberation I did the suspension dogbones in silver.  Decided the mechanical fittings will be silver, the main structure of the frame, forks etc black.

Prep has started on the frame.  Very little rust, and that's been rubbed back and rust treated.  Some more rubbing to do, then it'll be ready for pain.  On the plus side, most of the mounting tabs on the rear subframe for stuff like starter solenoid, indicator relay etc will be hidden by the seat unit I have planned, so minimal grinding and filing required.  Happy days.

Once the frame is fully prepped it'll be picture time again.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 15, 2016, 13:50:18
Frame now totally stripped.  Looks as if it's been various colours over the years.  Still, It's straight and true, virtually rust free, so no complaints.  Seems that a P.O. has filled the indents on the frame spars to made them smooth.  Looks like they've done a tidy job so I'll leave it be.

Time for rubbing and prepping, paint in the next week or so.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 17, 2016, 14:53:22
Frame rubbed down and primed.  Primer rubbed down again today, now ready for paint in the week.

Also rubbed down the rear wheel ready for paint. Once the frame is painted I want the back end, forks and wheels back on the bike so I've got a rolling chassis.  All the rear end hardware, shock, knuckle, linkages, spacers, torque arm etc are painted and ready to go.

So now a waiting game of several days while I wait for the paint to be delivered.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 21, 2016, 15:11:47
Been deliberating what to do with the wheels.  Ideally I would like them powder coated, but I'm on a tight budget and I'd like the save the pennies for things I can't do without or work around, such as new pistons or a pro rebuild of the head.

After much mulling and Googling of the problem I decided to spray them with bed liner. Cheap, tough, easy to touch in if damaged, and the thick nature of the coating hides minor imperfections.

I got hold of two cans of fine bed liner and started tonight.  Looks fantastic, lime a slightly textured powder coat.  I'm cuffed to bits.  I owe you guys some pictures so I'll show them off when I get a moment at the weekend.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Sep 21, 2016, 15:13:12
You may want to consider the bedliner for the frame too. I have read it is good and would tie in with the wheels.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 21, 2016, 15:42:22
Seriously considering it matey.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 22, 2016, 16:36:54
Back wheel finished.  Looks superb.  Going to do the disc rotor in the same stuff, seeing as I bought 2 x cans and the wheel barely used half of one. Pics as promised at the weekend ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 23, 2016, 06:39:18
Rear wheel...
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Sep 23, 2016, 14:04:57
looks pretty nice.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 23, 2016, 18:15:43
Thanks Maritime.  I'm chuffed to bits - the coat is crisp and even. You'd never know it wasn't powder coated, it's that tidy a finish.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Sep 23, 2016, 19:56:49
Rear wheel...


Looks great.  Think it will be tougher to keep clean? 
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 24, 2016, 06:10:38
I can see it needing a soft brush and a bucket of soapy water to get the dirt off.  A spray wax and a rag won't cut it here!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 24, 2016, 10:28:41
And today I have painted the frame.  I've carefully closed the shed door and i'll not disturb now for at least 24hrs to keep the dust down.  I'll venture in tomorrow afternoon and sneak some pictures.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Sep 26, 2016, 08:59:44
Did you use the same bed liner? can't wait to see it.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 26, 2016, 14:56:06
I did seriously consider the bed liner for the frame, but went with plan A and the hammered finish I had originally decided upon.

The visible parts such as the frame spars were sprayed, the areas that will be hidden by seat or bodywork, such as the sub frame, were hand painted with a final coat sprayed on.

I really should have left the frame to dry for longer, but couldn't resist some reassembly today, being very mindful of the still green paint.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 26, 2016, 14:56:53
I know not why the pictures are rotated 90 degrees anti clockwise.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 26, 2016, 14:57:51
When I can get some time in a proper pooter i'll re post these via Photobucket, get them them right way up.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 26, 2016, 18:54:52
A gratuitous FZR picture to grab your attention.

Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Sep 26, 2016, 19:44:30
Nice!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Sep 27, 2016, 17:27:28
The finish is a little gauche for my tastes, but the silhouette is close to what I'm aiming for.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Sep 28, 2016, 08:49:26
What the bright orange wheels and fuzzy seat not to your liking?  ;D
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 12, 2016, 07:27:23
Still beavering away.  Here's the front wheel.  The discs aren't rusty, It's a reflection of the flash off the brickwork.
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Oct 12, 2016, 15:11:06
You can't turn up on here and start using words like gauche.
It's that kind of language that causes international incidents.
😉


Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Oct 12, 2016, 15:14:14
Or anything to do with beavers.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 13, 2016, 13:08:14
I quite like beavers.  Wonderful animals  8)

Been working on the tail/seat unit today.  Got a tail from an early R6.  Jeez, are they wide or what?  I'm a big lad, almost 6-Four in my socks and 265, but I look like a toy perched on one.  To make matters worse, it's wider than the fuel tank cover and looks daft.  Not a problem - cut out 3" along the middle length -ways, and used the bits I chopped out to fashion braclets which I bonded with Sikaflex to reattach the two halves.  Lovely.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Oct 13, 2016, 13:27:19
Why does beaver taste like tuna?
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Oct 13, 2016, 13:45:42
The Limey, ask any girl in Canada to show you her beaver and you will either get lucky or punched LOL
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Oct 13, 2016, 17:37:11
What's this sikaflex all about? I need to repair a side panel, sounds like it might do the trick. I did a search and it came up with lots of different ones.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 13, 2016, 17:56:59
It's a high strength automotive adhesive, used for sticking spoilers etc to bodywork.  I had half a tube knocking about from another job.
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Oct 13, 2016, 19:14:24
Does it have a code number?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 14, 2016, 05:31:14
The stuff I used is Sikaflex EBT in black, which is their general purpose adhesive and sealant.  Plenty of 'Sikaflex EBT' on eBay and the like. Used properly it'll join sheet steel to sheet steel and give a stronger join than welding, and that's no bull.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 14, 2016, 12:33:12
Rubbed down and painted the fork sliders with PJ1 frame paint.  Nice.  New seals and oil ordered.

Had my first peer around the engine.  Peering down the inlets shows number 3 suspiciously full of rust.  Not so nice. Generous quantities of Duck Oil squirted down the ports and I'll start stripping the motor in due course.  I'm reckoning on a full top end rebuild at the very least.
Title: Re: FZR600 Neo-Cafe
Post by: Erskine on Oct 14, 2016, 17:03:18
The stuff I used is Sikaflex EBT in black, which is their general purpose adhesive and sealant.  Plenty of 'Sikaflex EBT' on eBay and the like. Used properly it'll join sheet steel to sheet steel and give a stronger join than welding, and that's no bull.

Thank you!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 14, 2016, 17:42:23
No worries. It's seriously good shizzle.  A friend of mine works for a defence contractor and he first put me onto it.  They use it for fitting spall liners to armoured vehicles, so you know it's good shit.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 15, 2016, 13:29:27
Slowly slowly buildee bike...
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 21, 2016, 16:18:19
Still waiting for fork seals and oil to arrive before I can get the front end on. While I've ground to a halt I've started slowly stripping the engine. Cams and bearings look excellent, as do the valve buckets. Very good news on that front.

I'm not looking forward to getting the head off and seeing what #3 jug looks like inside, but I'll know tomorrow.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Oct 21, 2016, 19:49:04
Show us the guts of the motor!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 09:25:40
Head off.  Mixed findings.

Rust on the valves of the centre chambers, so a head rebuild will be required.  The head is otherwise good, so may be worth it.

Barrels not so good.  Pot three was full of rusty water.  Shame, because the other bores look clean.  A wipe around with Duck Oil and scotchbrite shows the rust has etched the bore, so it would need a re bore, which would necessitate new pistons.

Which would be an expensive shame as the pistons all look good, minimal carbon, only the slightest of scuffing on the skirts.  I think it might be easiest  to get a new block, run a glazebuster through it and re use my existing pistons with new rings

Either way, the noise of cash registers going 'kerching' will feature prominently in my life soon.  Pics to follow soon.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Oct 22, 2016, 13:41:21
I wouldn't have thought a complete fzr or thundercat engine would cost as much as having your motor rebuilt, I doubt if it can be rebored.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 13:48:58
They can take up to a +1mm rebore, and +0.5 and +1 kits are available, but very expensive.

A whole engine is an option that I won't dismiss and will keep my eyes peeled.  However, good, low mileage complete engines go for proper money over here, and probably wouldn't save me much, or even anything, over the cost of a head rebuild and a second hand block.  There there's the risk of you never really know what you're getting...

I'm inclined to rebuild, but I'm keeping options open.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Oct 22, 2016, 14:49:19
If you're in the UK you can buy complete running but cosmetically challenged Thundercats, FZR600Rs and Fazer 600s for 800
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 15:33:15
Which is what I started with!  Tired old biked have tired old engines, more so if they're revvy small bore valvers.  I'm not dismissing the idea, but finding an engine with guaranteed provenance isn't likely to be easy.

Thundercat and the FZR-R motor is very similar, being derived from the Fizzer, but isn't a straight swap.  Chain line and mounts are different.  It can be done, but is a job of work.  In fact, swapping bits between 'cat and Fizzer you can build a 660.

I'm waiting for an email back but I'm looking the in the order of 250 for a head build, so with a used block and rings i'll have a motor running close to new spec.  Provided the bottom end is sound then lid rather do that than spend similar on another engine that'd probably be pretty tired itself.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 15:41:58
Here we are...
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 15:42:39
And...
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Oct 22, 2016, 16:53:12
That's a shame the one bore is shit.  Otherwise you'd have been fine.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 16:59:13
I know buddy.  Still, it's the first kick in the nuts of the whole project so I've not done so bad.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Oct 22, 2016, 17:11:26
Is yours an early FZR, I assumed it was the later FZR600R which has the same frame as the Thundercat.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Oct 22, 2016, 17:14:29
Just read your opening post, it's a 91 FZR, for some reason I thought it was the 94 onwards model, sorry, my mistake.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 22, 2016, 17:15:38
It's a 1991, 3he7.  One of the first generation bikes, albeit mine is one of the first of the revised models with 4 pot stoppers and the single headlamp fairing... not that it has any fairing left.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Oct 22, 2016, 21:39:53
Once the heads come off, it's 50/50 surprises eh?  Buggers on that bore.  Sounds like a good plan to rebuild rather than grab a "runner" block.  Mixed bag. 
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 23, 2016, 13:39:04
Cleaned up one of the pistons then started the next on soaking in solvent.

Then finished rubbing down the seat unit and primed it.  It's looking gewd.  Now I need to identify a white used by a modern car manufacturer that's ever so slightly off white, just sort of with a slight creamy tone to it.  Ideas that might be available in the UK?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 26, 2016, 14:16:45
Forks now rebuilt with new seals and oil, and refitted.  Front wheel now on the bike.

I have now reached that most motivating of milestones - a rolling chassis!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 30, 2016, 14:59:41
Finished modifying the R6 seat unit to fit. Where it's not visible it's been stitched together with alloy sheet and pop rivets.  However, the one join that will be visible has been made with real 1mm carbon fibre sheet and copper pop rivets.  The contrast between the ultra modern carbon and ultra vintage copper looks lovely, and a little be steampunk.  Just need to finish rubbing it down for paint.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 31, 2016, 13:20:08
Like this...

Oh, BTW, the rivets on the left will all be hidden from view when the unit is complete.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Oct 31, 2016, 13:28:23
Neat. I like that
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 31, 2016, 13:47:26
Thanks buddy :) I love the contrast between old and new. I've a few little touches like that planned, such as a polished brass exhaust hanger.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 01, 2016, 09:00:21
Well, November has arrived and with it night frosts.  Suppose I shouldn't grumble, only 900 miles south of the Arctic circle.

Weather dull and drizzly.  Although it's dry and snug in the workshop it's not ideal weather for painting.  Still, managed to spray the speedo bezel which had been filled and repaired.  Warmed the can beforehand and placed the piece near a heater, so should get away with it.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 02, 2016, 14:24:06
And here it is reassembled and better than new.  The budget won't allow anything snazzier, and although i'll be re using the original clocks I'll be mounting them differently.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 18, 2016, 18:14:08
Gone quiet lately, for which I apologise.

Putting the final touches to the chassis and bodywork.

Headlight now installed, and I'm progressing with the paint on the seat unit.

Mount for the clocks has been designed in my head, and is on the list.  Meanwhile, engine stripping continues.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 18, 2016, 18:14:58
And...
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Nov 21, 2016, 12:38:52
That tank is something else.  I like it.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 21, 2016, 13:50:16
Why thank you old chap.  It's very rare, so I'm keen to retain it. I've started painting the seat unit to match, which is going to be a major job of work!

I've been mulling the engine. As aforementioned, the barrels really need a rebore, gone beyond the potential salvation of a hone.  A rebore means new pistons, which means big money.

Been reading around and the mid nineties YZF motor is very similar, but has a fraction less stroke and a smidge more bore.  However, with the addition of a custom cut 5mm base gasket the YZF top end mates seamlessly to the FZR bottom end to give 660cc and, properly set up, just North of the magic hundred horsepower - ton up power for ton up performance.

This should also save me pennies as over here entire YZF (or FZR600R) too ends in good order can  had quite cheaply, so I can get more edge for less wedge.
Title: Re: FZR600 Neo-Cafe
Post by: johnu on Nov 21, 2016, 16:39:28
Bloody hell that looks wicked, nice work :)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 21, 2016, 17:11:02
Thanks guys.  Such kind words from fellow bike builders is the best encouragement there is.
Title: Re: FZR600 Neo-Cafe
Post by: NoRiders on Nov 21, 2016, 17:40:40
Just found this thread. I'm in  :D

Good to see a fellow Brit on here doing it. Liking that you've chosen an atypical bike/model and doing your own thing with it (much like my build), cool.

Shed built on a budget sorts the men from the boyz I reckon, but sometimes a spend is a must, bite the engine bullet and you'll move the project along nicely.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 21, 2016, 18:09:59
You're not a million miles from me Colin.  I'm on the boonies near Northampton. 
Title: Re: FZR600 Neo-Cafe
Post by: NoRiders on Nov 21, 2016, 18:21:33
You're not a million miles from me Colin.  I'm on the boonies near Northampton.

Ah no, you're not too far, have you been to the Skins Cafe in Brackley, great coffee and sell some nice riding kit?
Not a local, but not far from some biker mates (Honda 400twin cafe, Harley FatBoy and my Honda CBX Scrambler), enjoyed a ride out just before the weather changed.

(http://i77.photobucket.com/albums/j60/LemonBUG/20161015_150415_zpsm9qkkmib.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20161015_150415_zpsm9qkkmib.jpg.html)

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 21, 2016, 18:27:41
I know it - I was based at the cop shop there for a while - but never frequented it. Once I've got this bike sorted I'll be visiting a few such establishments ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 24, 2016, 05:59:49
Started rubbing down the engine covers for paint.  Going for a matte black.

Some good news.  The clutch has few signs of wear, looks very new in mileage terms, so some pennies saved there.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Nov 24, 2016, 08:32:24
Well that's always good. Glad to hear you figured out how to freshen the motor cheaper for more horses too.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 30, 2016, 15:30:20
Things are going slowly at the moment.  The weather is cold, -9C last night, barely above freeing by day, which makes the workshop rather painful to be in! It also makes it impractical to be applying paint.

On top of that I've knackered my shoulder and I'm supposed to be resting it completely for 6 weeks - bar the therapeutic exercises I've got to do - or risk needing surgery to fix it.

Still, things haven't stopped completely. I've sussed the final mounting of the seat unit and it's now got a solid white basecoat, so next stage is to start masking for the red stripes to be sprayed on. 

I've also got new levers and front master cylinder on the way, as well as some spanking new grips.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Nov 30, 2016, 16:14:07
Sorry to hear about the shoulder, Try not to make it worse. Good to hear you're keeping at what you can.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Nov 30, 2016, 16:21:53
It's -5ish here in East Anglia, I've got a Z1170 engine to get back together, but it'll have to wait until the weekend.

Get well soon, I hurt my shoulder cycling, it took ages to heal.
Title: Re: FZR600 Neo-Cafe
Post by: johnu on Nov 30, 2016, 16:43:09
 :o sorry to hear about the shoulder!  I've had 4 surgeries on my left shoulder and 3 on the right, all from racing accidents 8)  Rest it and take care of it, surgery is no fun :(  Bike will still be there when you are healed ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 30, 2016, 17:46:45
Had me elbow pinned back together some years back.  Combination of advancing years and favouring my bionic arm have weakened the shoulder making it unstable and now I got an impingement problem.  Hurts more than Hilary's election night.  Major bollocking from the Doctor - rest it or risk surgery.

On the plus side she's an attractive blonde lady, and when she was examining me she kept rubbing her norks on me so it isn't all bad!
Title: Re: FZR600 Neo-Cafe
Post by: johnu on Nov 30, 2016, 19:43:04
Had me elbow pinned back together some years back.  Combination of advancing years and favouring my bionic arm have weakened the shoulder making it unstable and now I got an impingement problem.  Hurts more than Hilary's election night.  Major bollocking from the Doctor - rest it or risk surgery.


On the plus side she's an attractive blonde lady, and when she was examining me she kept rubbing her norks on me so it isn't all bad!

I should image you will have to go back and have her look at it quite often then just to be sure it's progressing properly ;D
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 01, 2016, 04:52:59
Yes mate, I'm fairly sure I'll be needing regular check ups ;)
Title: Re: FZR600 Neo-Cafe
Post by: NoRiders on Dec 01, 2016, 07:51:53
....norks...!

Haha...haven't heard that term in a good while....probably on 'Porridge' TV comedy show  :D

GWS
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 02, 2016, 17:47:36
Today I've done some more masking and painting of the red stripes on the seat unit.  Boring, tiresome work.

I've also rubbed down and painted the bar end weights in satin black.  The Devil in is the detail ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 03, 2016, 10:09:24
Slow progress...

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 03, 2016, 10:12:04
And...

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 03, 2016, 10:12:50
And...

Title: Re: FZR600 Neo-Cafe
Post by: NoRiders on Dec 03, 2016, 10:56:12
And.......looking smart  :)

Will you be changing the mahoosive flashers by any chance?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 03, 2016, 11:19:33
Yeah, in due course. I'll get the bike complete and running then there'll be a second round of refining little points like that.  For now they stay in the interests of budget.
Title: Re: FZR600 Neo-Cafe
Post by: NoRiders on Dec 03, 2016, 11:45:54
Cool.



PS Gettin' neckache trying to look at your images  ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 14, 2016, 11:36:02
Things are progressing, albeit slowly because of the sub zero temperatures and my shoulder injury.

Continued to strip the engine, readying the cases for painting.  I'm thinking the side cases in a satin black, and the main castings in a black wrinkle finish.  Sexy.

I've finished painting the seat unit and laid on then first coat of clear.  I wanted to use spray max, but it's horrifically expensive over here and I'm building this in my works pension,  several hours surfing the internet revealed the existence of Rust-oleum Hard Hat paints.  High solids content, it's supposed to be super tough, intended as it is for industrial pipework, and lb. for lb. the clear lacquer costs about 1/4 that of spray max.

So I've ordered some and today layer on then first layer.  According to the label it's 11/10 on the scale of planet murdering nasties, always the sign of a decent paint;) It goes on thick and smooth, just like me.  I'll lay on a few more coats, and  hopefully it lives up to its super tough billing and proves more resilient than regular auto spray lacquer.  I'll report back on that one.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Dec 14, 2016, 11:47:18
since it isn't likely to get fuel on it you should be ok. I know the spraymax is 100% fuel proof. I spill fuel on the cx tank almost every fill up and just wipe with a paper towel, it still looks like it did 3 years ago.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 14, 2016, 11:58:16
As always, Maritime is wise.  Were I doing the tank then i'd have manned up and got my change purse out.
Title: Re: FZR600 Neo-Cafe
Post by: hooligan998 on Dec 14, 2016, 22:59:29
Slow progress...

Very nice tank!  I used to have the Bell helmet that matches it.  Wish I still had it.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 15, 2016, 04:06:24
I wish I had one too!

Apparently there was also a very limited run of V-Max's with the same paint.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 17, 2016, 21:38:04
Paint done, just needs to cure for final flat and polish.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 17, 2016, 21:39:49
And from another angle.

Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Dec 17, 2016, 21:55:24
Looks great.
Title: Re: FZR600 Neo-Cafe
Post by: johnu on Dec 18, 2016, 01:36:35
Awesome paint, how do you do that in such cold weather.  Nice work :)
Title: Re: FZR600 Neo-Cafe
Post by: CrabsAndCylinders on Dec 18, 2016, 04:24:10
Nice paint!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 18, 2016, 16:58:43
Awesome paint, how do you do that in such cold weather.  Nice work :)

Picked a mild day, heated up the workshop, and went for it.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 19, 2016, 10:01:54
Slight delay this week, after my car caught fire last night.  I'm going to be busy sorting out that mess before turning my attention back to the Fizzer.

On the plus side it was only a 12 year old Kia and no one was hurt, so it's not a hardship, just a temporary embuggerance.
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Dec 19, 2016, 10:25:59
Glad nothing serious happened, hopefully you can sort it out without too much time or money.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 19, 2016, 14:52:21
The ashen remains are being hoisted away tomorrow, and the following day it's replacement arrives. Virtually brand new in comparison, an 11 year old Ford Fusion.
Title: Re: FZR600 Neo-Cafe
Post by: julian.allard66 on Dec 19, 2016, 16:34:31
You're posh, we've got a 14 year old Ford Mondeo and a 16 year old Ford Puma.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 19, 2016, 17:03:07
I am post indeed. Our main car is a 66 plate, new one every 3 years (thanks Motability ;) )

I have zero love for or interest in cars, just so long as they're fairly reliable and cheap to run.  That said, I do much prefer driving them when they're not on fire.
Title: Re: FZR600 Neo-Cafe
Post by: Green199 on Dec 23, 2016, 13:41:33
This is looking pretty damn awesome! May have missed it but whats the special edition paint for?

Nice to see another UK work in progress.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jan 15, 2017, 17:55:00
Apologies for the lack of news recently. Things slowed a bit over Christmas, my nacked shoulder has been hampering me, and the Wife's health has been a bit dicey (she has MS).  But I'm still at it.

Seat unit now fitted.  Needs a final flat and rub, but it's on the bike for now.  Wiring loom repaired, cleaned and re wrapped. Work stripping the engine continues.

The paint was a special edition from the 'factory' here in the UK, 20 for the 1990 model year with the last of the original twin headlamp models, and 20 from 1991 with the single trapezoidal headlamp.  To my knowledge this is the only 1991 model surviving, so I wanted to re use as much of the original bodywork and paint as possible.  I know of only one surviving 1990 version, which is complete but rougher than Roseanne Barr without the make up.  I've not found out much about the models, and don't know if the paint was factory, or if the UK or European importer had them painted up, but they were certainly sold from the showroom floor like that.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 02, 2017, 19:27:19
I've not forgotten, the project is still alive.  Almost finished painting the engine.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 03, 2017, 11:38:44
Engine cases painted...

Title: Re: FZR600 Neo-Cafe
Post by: Rat_ranger on Mar 04, 2017, 05:17:08
I'm kind of surprised you didn't swap to a 3tj swingarm.  1\2" ahorter and a few pounds lighter, but the same shape.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 04, 2017, 07:25:01
Partly price, and partly wanting to not lose any stability through reduced W/B - important for a 260lb rider. It was one of the best handling bikes of its era and I doubt there's much a ham fisted Neanderthal like me could do to improve on it.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 04, 2017, 08:16:29
Clutch cover.

Title: Re: FZR600 Neo-Cafe
Post by: Rat_ranger on Mar 04, 2017, 13:18:08
Makes sense, I had a heck of a time finding a 3tj arm when I was building a 400.  Your bike will look better than new when you're done.  Keep up the good work.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 04, 2017, 13:22:32
Thank you Sir!  ;D  Some of those exotic FZR swingers do look nice though.
Title: Re: FZR600 Neo-Cafe
Post by: Rat_ranger on Mar 04, 2017, 13:30:43
Tell me about it, I have 3 400 swingers right now.  1 3EN, 1 3TJ, and 1 3TJ rrsp.  One of them will end up on my XS650. 
Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Mar 04, 2017, 20:24:05
Makes sense, I had a heck of a time finding a 3tj arm when I was building a 400.  Your bike will look better than new when you're done.  Keep up the good work.

+1 you're doing good work.
Title: Re: FZR600 Neo-Cafe
Post by: furu14 on Mar 05, 2017, 04:10:01
Good to see that others have found that the early "R" bikes can be done something with other than just tearing off the plastic. :)

I got a 87 fzr 1000 with "some work" done to it.. ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 05, 2017, 04:48:24
While I put the finishing touches to the bottom end, my thoughts have been turning to the radiator.

I'd far rather it were air cooled for the visual simplicity.  Well, it ain't! Standard radiator is a slab, zero attention to its appearance as it was designed never to be seen by man, hidden away as it was behind the fairing.

Browsing the interweb looking at rads I think I'll go with an early R6 model.  It's still a slab, but it has a curve to it and looks a bit more interesting.  Reckon I can do something good with one of them.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jul 06, 2017, 04:42:27
Still here.  Bottom end rebuilt, ready to fit in the frame.  In the interests of keeping the weight down and manageable I'll refit the top end when its in the frame.

Things have gone very slowly of late.  I have a duff shoulder, which has got much worse since earlier this year.  Im having an op next week, and hopefully I'll then recover sufficiently to carry on with the build.
Title: Re: FZR600 Neo-Cafe
Post by: Innamorata 750 on Jul 07, 2017, 22:29:38
Apologies for the lack of news recently. Things slowed a bit over Christmas, my nacked shoulder has been hampering me, and the Wife's health has been a bit dicey (she has MS).  But I'm still at it.

Seat unit now fitted.  Needs a final flat and rub, but it's on the bike for now.  Wiring loom repaired, cleaned and re wrapped. Work stripping the engine continues.

The paint was a special edition from the 'factory' here in the UK, 20 for the 1990 model year with the last of the original twin headlamp models, and 20 from 1991 with the single trapezoidal headlamp.  To my knowledge this is the only 1991 model surviving, so I wanted to re use as much of the original bodywork and paint as possible.  I know of only one surviving 1990 version, which is complete but rougher than Roseanne Barr without the make up.  I've not found out much about the models, and don't know if the paint was factory, or if the UK or European importer had them painted up, but they were certainly sold from the showroom floor like that.

My wife has MS too. she's switching to a new drug over the next few months. Hopefully that will go well.

Thoughts and prayers for your wife!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jul 08, 2017, 04:52:16
Thank you my friend!  ;D
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 27, 2017, 13:30:05
I'm still here.  Had some pretty horrendous shoulder surgery, so nothing done since June.  However, while it still troubles me I'm much more mobile now so work has resumed.  Huzzah!

Being old and wise I made sure the bike was cleaned, waxed, and all chrome and alloy was sprayed with Duck Oil before the bike was covered up, so it's emerged as good as the day it was parked up.  All the spares and finished parts waiting to go on were also sprayed in Duck Oil and wrapped in pieces of old sheets so they're also A1.
Title: Re: FZR600 Neo-Cafe
Post by: teazer on Oct 27, 2017, 14:40:15
Good to hear your shoulder is starting to improve.  Both mine are worn out and sometime soon I will have to go in for the replacement surgery and that means no bike work - or much of any other type of work for months.  Can't think why we keep avoiding things like that for as long as possible.  Make sure to do all the physio they require/recommend and get the strength and range of motion back.

And then get that bike finished in time for next spring riding. :-)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 28, 2017, 11:44:47
Roger that, I'm being a good boy with the physio.  It helps that she's a fit wee Latvian lass who wears the sexiest little glasses...  :P

It might be in the road for spring.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 31, 2017, 12:20:52
Tidied up the rear loom. Made a large alloy plate to mount the rectifier, and identified the indicator wiring.  It was a mess, so trimmed it back and will solder in some new wife in due course.

My under tail panel is almost finished too.

Title: Re: FZR600 Neo-Cafe
Post by: teazer on Oct 31, 2017, 12:34:26
..................  It was a mess, so trimmed it back and will solder in some new wife in due course.

...


Now that would be something to see...   :-)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Oct 31, 2017, 12:50:28
Ha ha! No more new Wives for me - too expensive!  :o
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 01, 2017, 15:09:52
Time to spruce up my new barrels, see what they're like under the crud.

Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Nov 01, 2017, 18:04:25
Mine just saw that pic of your cylinders in the dishwasher and asked about it.  After I explained, I heard "don't even think about it."
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 01, 2017, 18:46:40
Fortunately for me Mrs Limey will never know.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 02, 2017, 12:22:29
Bottom end refitted.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 02, 2017, 12:23:23
Rear indicators and undertail panel fitted.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 02, 2017, 13:48:18
Decided I'm going to go for an early ZX6R rad.  There ain't no getting away from it, the old bus is liquid cooled and no matter how I try and disguise it there's still a dirty great radiator sitting out front.  Therefore, it may as well be the big, butch looking, concave-curved Kwaka job. 
Title: Re: FZR600 Neo-Cafe
Post by: Uglyrabbit on Nov 02, 2017, 19:11:21
That will look good!


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 06, 2017, 07:54:25
Decided to fit a different rear light so removed the undertail panel to have a furtle to make it fit.  Then rolled her out into the sun for a clean.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 12, 2017, 12:03:25
New rear light fitted.

Number plate bracket made up, and number plate fitted.

A bit of tidying up done on the loom.

Fuel tank fitted - the nicely painted thing that you see is a dummy.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 16, 2017, 06:47:28
Refurbished fuel pump refitted, but not yet plumbed in.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 16, 2017, 06:49:06
And some Good ridge goodness.

Title: Re: FZR600 Neo-Cafe
Post by: teazer on Nov 16, 2017, 15:53:05
I used to get my Goodridge hoses and fittings from a place in the UK, BSR I think they were called. Run by Wendy Grant after he husband Dave died.  It was a reasonable sized operation in Chipping Camden IIRC. They closed some years ago unfortunately.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 16, 2017, 15:56:16
These came with the bike.  Unfortunately, they didn't have the stainless banjos but had the nickel played ones and they'd gone all manky.  A good rub down and a spray with silver Rustoleum appliance enamel and the look good as new.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Nov 16, 2017, 17:28:13
Refurbished fuel pump refitted, but not yet plumbed in.

Is that a stock setup on that bike?  On the 750, it's an internal unit in the tank. 
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 16, 2017, 17:46:12
Affirmative, its the stock item.
Title: Re: FZR600 Neo-Cafe
Post by: teazer on Nov 16, 2017, 17:52:17
Looks like the same pump as on our FZR400.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Nov 16, 2017, 17:56:39
Could well be.  The 4 and 6 are very closely related, to the point where the engine from the 6 bolts straight into the 4 frame.
Title: Re: FZR600 Neo-Cafe
Post by: teazer on Nov 16, 2017, 18:03:21
There have been a few 4/600s or mix and match bikes raced over the years.  I'd really like a MotoGP M1 shaped seat.  I think it could be made to work well with the lines of a 400 or 600.  Ours has the old stock flabby assed seat side panels.  Yours is much better looking. 

A YZF600R tank would work nicely but they are a little rounder and fatter at the rear that the stock tank cover.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 04, 2017, 06:26:53
OK, my plans forma ZX6R radiator have fallen by the way side.  In the Box O' Shite (tm) I found the radiator.  It was actually pretty straight and in good order.  Better still, there was a nice stainless shield in there.  A good clean up, repaint the rad, and on it went.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 04, 2017, 06:38:09
Instruments mounted.  Made the bracket myself and painted it.  It looks a bit prominent up there in the breeze, but fear not as I have a plan.

Big up to my mate "Old Man" Mac who supplied the alloy plate.  He's a top bloke, even if he does smell of piss and cabbage.  He's a biker himself and is the father of the Yamaharley.  Here's his website...

http://www.scavengers.club/?author=3
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 04, 2017, 06:39:57
And I've refitted the clutch and starter gear covers.  I'm particularly pleased with the finish on these.

Title: Re: FZR600 Neo-Cafe
Post by: Odontologist on Dec 04, 2017, 06:47:05
Nice. SS allen bolts look good against black. Is that finish in clutch cover etc tin can paint? If so, do you know how it hold up ??
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Dec 04, 2017, 06:59:48
Its a fine spray bed liner from a can.  It's extremely tough.  The photos don't really domit justice - viewed directly it looks very similar to the Harley black crinkle finish, but a third the price and many times more durable.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jan 03, 2018, 10:29:09
Wasn't too happy with the clocks.  Too big and bulky.  A rummage through my Box O' Shite  (tm) revealed a small flyscreen, but that was still to small to hide the carbuncle that was the instruments.

So, had to put my hand in my pocket and get a mini speedo.  The idiot lights will be mounted either side, and you can see the mounting holes I've already drilled for those.

Thin thinking a Stack temp gauge can be mounted flush in the tank, but I will probably forego a tacho.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Mar 01, 2018, 03:26:26
All work has come to a halt.  Its -8C in the workshop, and I'm a soft southerner.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 16, 2018, 08:42:25
The weather is now warm enough to resume work.
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Apr 16, 2018, 12:16:21
Right on!
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 16, 2018, 13:20:22
 Thanks Bro.  I've not got the engineering talent equipment or budget of some guys in here, but I've done my best to keep it on target. 
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 26, 2018, 09:07:33
Today I've made a start cleaning and de rusting the rather nice 4-2-1 downpipes.  They're actually in pretty decent shape.  The corroding is minor and coming off well.  I'll rust-kill it when its done, and then repaint.  I'm not sure yet if ull wrap when or not.  I'm thinking not, but we shall see.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 27, 2018, 15:19:32
Have a wank on me.  Er, not literally though.

Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 27, 2018, 15:22:23
Oh, go on then.

Title: Re: FZR600 Neo-Cafe
Post by: Maritime on Apr 27, 2018, 15:23:54
Sexy
Title: Re: FZR600 Neo-Cafe
Post by: canyoncarver on Apr 27, 2018, 16:25:32
Nice pipe!.  I see a valve cover there.  Got a nudie shot of the cam chest?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 27, 2018, 16:38:11
Sorry buddy, need a new head.  When I pick one up I'll do you a full front shot with the lobes hanging out  ;)
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Apr 29, 2018, 11:15:17
Front pipes cleaned up and painted.
Title: Re: FZR600 Neo-Cafe
Post by: teazer on May 01, 2018, 00:37:30
Go on.  Flash her lobes for us. 

I'd speculate that many people on here have not seen inside a 16 valve motor before and might be interested to see how far engines progressed from say a Cb360 to an FZR.  A whole generation of difference.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on May 15, 2018, 08:43:58
 Engine block refitted.  Now need to find a cylinder head to sit on top.
Title: Re: FZR600 Neo-Cafe
Post by: hooligan998 on May 16, 2018, 01:07:46
Love that JK paint scheme.  Did you get a helmet to match it?
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on May 16, 2018, 03:24:02
Not yet, althpugh im keeping my eyes peeled.

I saw a V-Max for sale recentky with the same paint job.  Was very tempting...
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jun 08, 2018, 15:31:46
Time spent in the workshop today.
Title: Re: FZR600 Neo-Cafe
Post by: The Limey on Jun 09, 2018, 12:30:19
Playing with the seat fitting.