Another DIY Cafe-style Seat

[halfton]

I'll try and make this brief....

After years of owning scooters I deciding to try a new project and recently purchased an original condition, low-mileage, '69 Kawasaki. 90cc two-stroked single cylinder of fury called a Bushmaster with a picture of a snake on the side...couldn't pass it up.

I immediately made some clubman bars, bought new tires, minor tune up, pulled a dent, stripped, and cleaned the tank then began sourcing a few parts. The next step was how to make a seat. I've read many of the great DIY seat threads and since I'm I welder decided to go the metal route. The problem was finding the right quarter-sphere shape I wanted. Looking at my old skateboard helmet in my garage one night gave me the idea...if only it were made of metal. After a quick search for "steel helmet" on epay it was obvious that a military helmet would do the trick. This I was told was a post-Vietnam steel helmet pot which I was able to get for under $20 shipped pictured next to a spare Kawasaki seat I stripped and blasted.

After some trimming and blasting

and after a few tacks, soon to be fully welded and eventually covered

I was going to wait to post until it was finished but with so many other things that may be a while. Besides, this is the important step, the rest is obvious. thanks, graham

 

[locOleoN]

very nice!...
What tank are you running on that bike?

 

[HerrDeacon]

Great idea on using the helmet, will be quite a conversation piece. Great job.

 

[halfton]

thanks. it's the original kawasaki tank.

 

[Ease]

Very cool!

I'd have left the rim / paint on it and painted the tank to match!

;D

 

[Elnogue]

Wow!
So nice!
I've got a very similar idea to make to my '66 Bultaco 125cc.

I love that little and funny bikes!

 

[maxypants]

That looks awesome! Anymore updates of the seat with foam and covered?

 

[kneedragger]

Man, I like that idea; glad you could put that old steel pot to use. Very original approach; can't wait to see more of your work.

Any chance you'd be willing to post some photos of the clubman bars you fabricated? I'm sure I'm not the only one who wants to see what you came up with...

Thanks; I'll be watching for your updates...

-- kd

 

[halfton]

i appreciate the comments,

not much progress on the seat. so far only added a back plate. i originally wanted to only frame it so i could use the back space as a glovebox and access it by unsnapping the rear cover and removing a small piece of foam. decided that it wouldn't be as useful for the amount of trouble to go through all that.

had to make my own clubman bars since it's such a small bike. the regular one would have been to large. i just bent up some 7/8 x .188 DOM round tube we always carry at my work. i didn't have anything to go by so i just welded one bar out to where i thought looked/felt alright then matched the other. it's a little awkward and maybe could be in a better position but i'm happy them.

my next task will be a pedestrian slicer (front fender number plate).

 

[Docta Jones]

Man, that seat is perfect. I had been trying to think of something just like that that I could just chop off and use. Couldn't think of anything. I love the half bubble, especially on a small bike. Kudos to you!

 

[ridesolo]

I made a trip out to a surplus store yesterday to get an old helmet. No luck! Jeez, you'd think that an Army/Navy Surplus Store would have a few steel pots laying around! :'(

 

[drewvdubber]

any pics of this complete? i sourced a helmet and i am ready to try this. i really would like to see a finished product. ;D

 

[maxypants]

I went with this same route. You can check out photos of my bike in the show and shine, the 72 suzuki. I built my own seat pan instead of using an old one. The only thing that I disliked about going this route was that drilling threw the steel helmet to put in snaps was near impossible. I had to take it to my friends machine shop where we burnt threw two pure carbon bits.

 

[drewvdubber]

ahahahahah thats awesome, good thing i have access to tool and die shop.

 

[hopterfixer]

I went with this same route. You can check out photos of my bike in the show and shine, the 72 suzuki. I built my own seat pan instead of using an old one. The only thing that I disliked about going this route was that drilling threw the steel helmet to put in snaps was near impossible. I had to take it to my friends machine shop where we burnt threw two pure carbon bits.

How fast were you spinning that bit?

 

[maxypants]

How fast were you spinning that bit?

Fairly? Not sure of the exact speed, the bits are sharpen able anyways so it's not like they are garbage. I bought a set of brand new drill bits before taking it there, they hardly made a mark on that metal.

 

[Koestum]

Any updates on this seat project since August? I'd like to see some pics if it's finished yet.

 

[halfton]

Any updates on this seat project since August? I'd like to see some pics if it's finished yet.

Actually I do...finally got it covered a few months ago:

I wasn't real happy with the upholstery so I wasn't in a hurry to post some pictures. There was a pit of a language barrier with the upholsterer who wrote "motosickle seat" on my order form.

But I like the feel and look of it all the same. Maybe should bob the fender and relocate the tail light but I'm fine with how it is.

 

[Koestum]

The bike looks great! Good job on the seat and thanks for the update. What a difference a few changes, some paint, and cleaning can make.

 

[halfton]

Thanks alot!

You can also see I've added a mirror. The result of being pulled over for not having one and getting hit for no registration and insurance to boot. I was just "testing" the bike out to make sure it ran okay before taking it to the DMV . Judge only tagged me for a $100 though.