76 XL250 "Cafuro" - DONE WITH PICTURES!
- Thread starter Mark in Seattle
- Start date
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Hey Honeybadger, I'm in the Central District, but afraid I only have access to a bandsaw at work and I'm already abusing that priviledge, sorry. I bet if you start a thread someone will hook you up.
Franken, the throttle linkage will be really low tech so prepare to be underwhelmed, hard to explain without pics, stay tuned!
Hey Honeybadger, I'm in the Central District, but afraid I only have access to a bandsaw at work and I'm already abusing that priviledge, sorry. I bet if you start a thread someone will hook you up.
Franken, the throttle linkage will be really low tech so prepare to be underwhelmed, hard to explain without pics, stay tuned!
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Another ebay find was these stainless engine bolts, done as a kit for my exact bike. Amazing, this seems like an obscure bike to work with so I was so surprised to stumble on these. I think they were only like 25 bucks too, all labelled for where they go - check out this guys site it's Stainless Cycle on ebay. He can probably do a kit for yours if he doesn't have one already. I'll post a shot when I get them on
IMG_2781 by Mary Mack & Mark, on Flickr
Another ebay find was these stainless engine bolts, done as a kit for my exact bike. Amazing, this seems like an obscure bike to work with so I was so surprised to stumble on these. I think they were only like 25 bucks too, all labelled for where they go - check out this guys site it's Stainless Cycle on ebay. He can probably do a kit for yours if he doesn't have one already. I'll post a shot when I get them on
IMG_2781 by Mary Mack & Mark, on Flickr
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Finished the cowl/seat today - finally! its a little rough, and the sharp corners may not look that pro, but it looks decent on the frame. Definitely feels like a "version 1", a learning curve attempt. probably skim coat some Bondo on there and sand a bit before paint. Anyone recommend a good covering primer and paint from a rattle can? (I'm through spending bucks on this baby)
IMG_2793 by Mary Mack & Mark, on Flickr
Finished the cowl/seat today - finally! its a little rough, and the sharp corners may not look that pro, but it looks decent on the frame. Definitely feels like a "version 1", a learning curve attempt. probably skim coat some Bondo on there and sand a bit before paint. Anyone recommend a good covering primer and paint from a rattle can? (I'm through spending bucks on this baby)
IMG_2793 by Mary Mack & Mark, on Flickr
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Starting to play with graphic ideas, my tendency is toward clean like my original mockup, but I could get out of my comfort zone with some more distressed looks like this one. Thinking of a very intentional look so its not "faux aged", but also holding the line on not becoming too "art bike". Still not sure, what do y'all think?
bikepaint1 by Mary Mack & Mark, on Flickr
Starting to play with graphic ideas, my tendency is toward clean like my original mockup, but I could get out of my comfort zone with some more distressed looks like this one. Thinking of a very intentional look so its not "faux aged", but also holding the line on not becoming too "art bike". Still not sure, what do y'all think?
bikepaint1 by Mary Mack & Mark, on Flickr
kopcicle
antidisestablishmentarian
Re: 76 XL250 "Cafuro"
Just a suggestion . Get it running then get creative . Some of my best constructs have been assembled twice with appropriate (or just downright brain dead) modifications in between . Did I say twice ? I meant ....
Hope to see the project in the flesh as soon as time allows
~kop
Just a suggestion . Get it running then get creative . Some of my best constructs have been assembled twice with appropriate (or just downright brain dead) modifications in between . Did I say twice ? I meant ....
Hope to see the project in the flesh as soon as time allows
~kop
dean owens
Pittsboro, NC
Re: 76 XL250 "Cafuro"
i'm looking forward to seeing this completed. the jury is still out on the bars. are they going to be comfortable? right now i'm not diggin' 'em, but i really want to see the whole thing together. it's hard for me to catch someone else's vision. but i've been pleasantly surprised on this site a number of times.
i'm looking forward to seeing this completed. the jury is still out on the bars. are they going to be comfortable? right now i'm not diggin' 'em, but i really want to see the whole thing together. it's hard for me to catch someone else's vision. but i've been pleasantly surprised on this site a number of times.
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Got my swingarm back , yes its chrome. Was going for nickel but the plater said it would stain and I'd need it clearcoated. So I switched to chrome. Not really a fan, probably should have painted it, looks too "show bike". Ah well, another expensive lesson. Its possibly the only chrome XL250 swingarm in existence LOL. I ground off the chain cover brackets but left on the rear peg mounts because they are a full wrap-around welded piece of steel and would have been crazy to get off. really over-engineered, not sure what honda was thinking on those, were sumo wrestlers passengers on these in 1976? Probably just put cap bolts in the holes, they'll be there for back pegs if I ever change this back to a 2-up seat. The project is moving really slow right now which is frustrating because it feels much closer. Can't seem to get anything done with an hour here and there, and feel like taking two days off work to get it roller and engine'd. I'm sure lots of people go through this phase. I'll keep picking away at it!
Chromed swingarm - oooh fancy-schmancy! by Mary Mack & Mark, on Flickr
Got my swingarm back , yes its chrome. Was going for nickel but the plater said it would stain and I'd need it clearcoated. So I switched to chrome. Not really a fan, probably should have painted it, looks too "show bike". Ah well, another expensive lesson. Its possibly the only chrome XL250 swingarm in existence LOL. I ground off the chain cover brackets but left on the rear peg mounts because they are a full wrap-around welded piece of steel and would have been crazy to get off. really over-engineered, not sure what honda was thinking on those, were sumo wrestlers passengers on these in 1976? Probably just put cap bolts in the holes, they'll be there for back pegs if I ever change this back to a 2-up seat. The project is moving really slow right now which is frustrating because it feels much closer. Can't seem to get anything done with an hour here and there, and feel like taking two days off work to get it roller and engine'd. I'm sure lots of people go through this phase. I'll keep picking away at it!
Chromed swingarm - oooh fancy-schmancy! by Mary Mack & Mark, on Flickr
Mark in Seattle
You must go too far, to know what is far enough
Did the triple tree bearings
Well I finally realized I should do an entry title to make the build thread better!
Got the AllBalls taper bearing upgrade since it was pretty cheap As other here have mentioned they have no install guides or tech support so you have to figure it out yourself. I think I did it right, they seem OK. I used the "heater on the frame, races in the freezer" (or the opposite in the case of that bottom bearing shown) to help the tolerances but don't know if it helped much - I still had to tap tap tap all around to get everything seated. That was my biggest concern (whether they were seated) since you can't really see or feel in there. But you can definitely feel/hear a difference in the tap when they are seated so thats good. You can also see a peek of my frame still in shrinkwrap, back from the powdercoater. It looks great (80% gloss black) but I'm sure experienced builders will laugh at this rookie lesson: "do ALL fabrication before paint or powdercoat" as I already nicked it working on the seat cowl! You can see I ground off the steering lock but I kept the fender mounts, not sure what I'm doing on the front, whether a high or low fender, but they could also be used for a headlight cowl I have in mind, we'll see
Forks are next, stay tuned 8)
IMG_2989 by Mary Mack & Mark, on Flickr
IMG_2991 by Mary Mack & Mark, on Flickr
Well I finally realized I should do an entry title to make the build thread better!
Got the AllBalls taper bearing upgrade since it was pretty cheap As other here have mentioned they have no install guides or tech support so you have to figure it out yourself. I think I did it right, they seem OK. I used the "heater on the frame, races in the freezer" (or the opposite in the case of that bottom bearing shown) to help the tolerances but don't know if it helped much - I still had to tap tap tap all around to get everything seated. That was my biggest concern (whether they were seated) since you can't really see or feel in there. But you can definitely feel/hear a difference in the tap when they are seated so thats good. You can also see a peek of my frame still in shrinkwrap, back from the powdercoater. It looks great (80% gloss black) but I'm sure experienced builders will laugh at this rookie lesson: "do ALL fabrication before paint or powdercoat" as I already nicked it working on the seat cowl! You can see I ground off the steering lock but I kept the fender mounts, not sure what I'm doing on the front, whether a high or low fender, but they could also be used for a headlight cowl I have in mind, we'll see
Forks are next, stay tuned 8)
IMG_2989 by Mary Mack & Mark, on Flickr
IMG_2991 by Mary Mack & Mark, on Flickr
MotorbikeBruno
Over 1,000 Posts
Re: 76 XL250 "Cafuro"
Yup, been there and done that...it looks perfect and then you realize you forgot to weld something or you need to move something. Looks really cool so far man. Can't wait to see this one put together.
Yup, been there and done that...it looks perfect and then you realize you forgot to weld something or you need to move something. Looks really cool so far man. Can't wait to see this one put together.
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
BTW thanks for all the comments it really helps to know someone else is looking forward to seeing it! Rev I agree thats a good point on the shiny forks to balance (also LimeSpider looks rad!), Bruno you and I both can't wait -
I'm having a little crack in my back rim welded today and then I hope to paint them today also. I feel like I can get 'er roller next week so stay tuned
BTW thanks for all the comments it really helps to know someone else is looking forward to seeing it! Rev I agree thats a good point on the shiny forks to balance (also LimeSpider looks rad!), Bruno you and I both can't wait -
I'm having a little crack in my back rim welded today and then I hope to paint them today also. I feel like I can get 'er roller next week so stay tuned
Mark in Seattle
You must go too far, to know what is far enough
rubber on the rims
I got my wheels painted silver and then to Twinline to use the tire machine to mount the tires - using Shinko 705s for a dual-sport look. When we were there I got to meet Keo Rock - actually he did the mounting - thanks K! Keo is a fixie bicycle rider who does freestyle tricks amazing enough that he has his own DVS shoe model. He also designed and handpainted a KZ650 that blew me away. What you call "One Talented Mutha"! Unfortunately I'd forgotten my phone so no pics, but here is a video link of Keo's fixie riding:
<iframe src="http://player.vimeo.com/video/14629953?title=0&byline=0&portrait=0" width="400" height="225" frameborder="0"></iframe><p><a href="http://vimeo.com/14629953">KEO ROCK</a> from <a href="http://vimeo.com/user2729014">HHIIRROO</a> on <a href="http://vimeo.com">Vimeo</a>.</p>
I got my wheels painted silver and then to Twinline to use the tire machine to mount the tires - using Shinko 705s for a dual-sport look. When we were there I got to meet Keo Rock - actually he did the mounting - thanks K! Keo is a fixie bicycle rider who does freestyle tricks amazing enough that he has his own DVS shoe model. He also designed and handpainted a KZ650 that blew me away. What you call "One Talented Mutha"! Unfortunately I'd forgotten my phone so no pics, but here is a video link of Keo's fixie riding:
<iframe src="http://player.vimeo.com/video/14629953?title=0&byline=0&portrait=0" width="400" height="225" frameborder="0"></iframe><p><a href="http://vimeo.com/14629953">KEO ROCK</a> from <a href="http://vimeo.com/user2729014">HHIIRROO</a> on <a href="http://vimeo.com">Vimeo</a>.</p>
Jake73
New Member
Re: 76 XL250 "Cafuro"
Funny, you almost caught a glance of my project. I just picked my bike up from Twinline yesterday; it was being dyno tuned. Those guys down there are great. Nice work on the project and check in on mine.
http://www.dotheton.com/forum/index.php?topic=21058.0
Funny, you almost caught a glance of my project. I just picked my bike up from Twinline yesterday; it was being dyno tuned. Those guys down there are great. Nice work on the project and check in on mine.
http://www.dotheton.com/forum/index.php?topic=21058.0
Mark in Seattle
You must go too far, to know what is far enough
76 XL250 "Cafuro" rear triangle on
Bolted up the rear last night, looks pretty shiny! Those are chinese shocks, obviously they are more for style than performance and they were SO cheap. This whole build is more about show than go, it's just a 250cc to be blasted around town, and that is still fun as heck! That riding plan has really freed me up to play with some experimental stuff like my bars that I might not feel safe trying on a freeway bike.
IMG_3002 by Mary Mack & Mark, on Flickr
Totally digging the look of that Shinko 705, looks very "dirt" without being a knobby and again...cheap! (And yes I realize that you get what you pay for). Onward to the forks!
Newly painted rear wheel with tire - Shinko 705 by Mary Mack & Mark, on Flickr
Bolted up the rear last night, looks pretty shiny! Those are chinese shocks, obviously they are more for style than performance and they were SO cheap. This whole build is more about show than go, it's just a 250cc to be blasted around town, and that is still fun as heck! That riding plan has really freed me up to play with some experimental stuff like my bars that I might not feel safe trying on a freeway bike.
IMG_3002 by Mary Mack & Mark, on Flickr
Totally digging the look of that Shinko 705, looks very "dirt" without being a knobby and again...cheap! (And yes I realize that you get what you pay for). Onward to the forks!
Newly painted rear wheel with tire - Shinko 705 by Mary Mack & Mark, on Flickr
Mark in Seattle
You must go too far, to know what is far enough
Re: 76 XL250 "Cafuro"
Jake thats crazy what a small world! Do you mind me asking what Twinline charged you to dyno tune your bike? and of course I'm curious to know if you got a horsepower rating with your 285 upgrade
Jake thats crazy what a small world! Do you mind me asking what Twinline charged you to dyno tune your bike? and of course I'm curious to know if you got a horsepower rating with your 285 upgrade
IndieSol
"This one goes to eleven." -Nigel Tufnel
Re: 76 XL250 "Cafuro"
Cool project. I can't wait to see what's next. I think that swingarm looks amazing. It's gonna look even better with some road grit on it. Can't wait to see this thing finished.
Incidentally, I'm looking for an XL250 to thrash around on during the winter and take hiking. They're great bikes.
Cool project. I can't wait to see what's next. I think that swingarm looks amazing. It's gonna look even better with some road grit on it. Can't wait to see this thing finished.
Incidentally, I'm looking for an XL250 to thrash around on during the winter and take hiking. They're great bikes.
Jake73
New Member
Re: 76 XL250 "Cafuro"
Haha yeah. We have to park these XL's next to eachother, this is too good. I'm friends with Hightower so I traded work with him. They would give you a great deal though, I'm sure. I'm not certain what my numbers are, it was just sort of a preliminary tune to get her running smooth. I have a baffle coming for my exhaust and am going to tune for power after I hook up a battery and get that in.
Our biked have 25hp from the factory, not bad for a now 260ish lb, 250. I would be happy with a few more horses, of course. I'm not sure what to expect though. I'll let you know, man - keep up the good work.
SeattleMark said:
Haha yeah. We have to park these XL's next to eachother, this is too good. I'm friends with Hightower so I traded work with him. They would give you a great deal though, I'm sure. I'm not certain what my numbers are, it was just sort of a preliminary tune to get her running smooth. I have a baffle coming for my exhaust and am going to tune for power after I hook up a battery and get that in.
Our biked have 25hp from the factory, not bad for a now 260ish lb, 250. I would be happy with a few more horses, of course. I'm not sure what to expect though. I'll let you know, man - keep up the good work.
