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Author Topic: 1983 XV500 Cafe Racer  (Read 41105 times)

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #70 on: Oct 13, 2013, 14:20:20 »
Bit of progress, hopefully I'll be able to a bit more next weekend.

Offline johnu

  • DTT BOTM WINNER
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  • Posts: 1441
Re: 1983 XV500 Cafe Racer
« Reply #71 on: Oct 13, 2013, 19:31:39 »
I'm using a standard 4 inch grinding disc.  I will invest in a flap disc, I should have thought of that!  Cheers for the steer.

What grit are you using?

Definitely use the flap wheels, so much better than the hard grinding wheel.  Even with the flap wheel I usually just get it close and the the last bit of material I remove with a file.  You really don't want to gouge the tube especially the headstock.

Too bad about the lathe but typically the slides can be adjusted and tightened up.

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #72 on: Oct 14, 2013, 14:05:14 »
Doh!! Bit late already a couple of gouges! I might have to do a bit of remedial welding in a couple of areas, nothing much, just cosmetic/vanity!!
« Last Edit: Oct 14, 2013, 15:02:46 by Karlloss »

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #73 on: Oct 20, 2013, 11:23:04 »
I've decided to manufacture a new headstock after all, the original one has too many defects, one being where the lock stop has been hit hard and deformed it, I'm guessing from a crash or something, trying to straighten it is a pain, plus cutting off the old frame mounts and other brackets I've cut into the tube more than I wanted. 

So I'm going to construct a new headstock. On a plus side, I've coped/fish mouthed the frame to take the new headstock, changing the steering head angle from 29 degrees to 25 degrees, that should quicken up the steering and move away from the lazy chopper steering. 

I'm quite pleased how the coping has turned out.

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #74 on: Oct 20, 2013, 11:24:28 »
More pictures

Offline wynand2000

  • Posts: 100
Re: 1983 XV500 Cafe Racer
« Reply #75 on: Oct 20, 2013, 11:45:27 »
This looks great! Maybe you can even copy the system Ducati`s have....they have some sort of adjustable headstock trick whereby they can adjust the degrees wished for an that certain track.

Keep up the good work

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #76 on: Oct 20, 2013, 16:34:14 »
This looks great! Maybe you can even copy the system Ducati`s have....they have some sort of adjustable headstock trick whereby they can adjust the degrees wished for an that certain track.

Keep up the good work

Thanks, I think an adjustable headstock may be a bit much for my fabricating skills, although I'm thinking of reducing the rake to 24 degrees.

Offline xb33bsa

  • Posts: 7727
Re: 1983 XV500 Cafe Racer
« Reply #77 on: Oct 20, 2013, 17:22:22 »
your work looks good but the upper mounts should have not been welded with a plate across the tube and the gusset on centerline is wrong
not that you totally failed i am just sying now you should add some outer gussets
2 plates running alongside the outer edge of the tube is the better way
same thing with your headstock run your gussets on the outside
dont run a single gusset on the inside centerline ;)

Offline Karlloss

  • Posts: 208
Re: 1983 XV500 Cafe Racer
« Reply #78 on: Oct 21, 2013, 15:25:15 »
the upper mounts should have not been welded with a plate across the tube and the gusset on centerline is wrong
not that you totally failed i am just sying now you should add some outer gussets
2 plates running alongside the outer edge of the tube is the better way
same thing with your headstock run your gussets on the outside
dont run a single gusset on the inside centerline ;)

I'm curious, why do you say this??

Offline xb33bsa

  • Posts: 7727
Re: 1983 XV500 Cafe Racer
« Reply #79 on: Oct 21, 2013, 17:27:29 »
its not stucturally good to weld across a tube it can bend/weaken the tube as well as creating a stress concentration in the excact wrong direction
it is pretty much common knowledge of frame building what I have said, not something I made up
you do good work but design wise it would behoove you to look at some existing frames and see the themes on gussets and mounts etc