CX500 Cream Cafe *Updated tank and seat*

Re: CX500 Cream Cafe

Look at what just came out of my tank!!!

0226001525.jpg


After doing electrolosys for a few days the water froze, so i brought it inside let it melt and after I sprayed it out I was able to pull out this huge chunk of old liner. For reference that is a regular pop can next to it. There is still a little bit of liner left in the tank, hopefully its not too much work to get the rest out.
 
Re: CX500 Cream Cafe

Man oh man i can't believe I have neglected updating this thread. So many updates to post.

Frame:

First off I used a grinder, file, and little bit of body filly to mold the sheet metal to the frame, i didn't want any visible welds since that part of the frame has the stamped look. Oh and i even thru some primer on it.

0304001638.jpg


I'm waiting till I get my seat (which should be here today!) to paint it, because further frame mods may be necessary.

Fender:

I also have "bobbed" my front fender. I marked off the line with painters tape to give my a guide and protect the chrome.

0305001854.jpg


0305001855.jpg



After getting the ruff cut I used a bench grinder and to get the shape closer, and then filed down the edges, no chance of getting cut on a sharp edge.


0305002059.jpg


I still need to drop the fender down a bit more.


Seat:
As mentioned above I decided to buy a seat. There not really that much, so i figured it would be worth saving me the frustration of working with fiberglass. I got the seat from ebay from the seller neuxstone. I bought the manx style one shown on this page http://legendary-motorcycles.com/retrocaferacerparts.html I got it unfinished and plan on useing closed cell foam that is being sold on this board.

Here is a picture of my C.A.D. mock up

0305002112.jpg


Does that tank look like its sitting a bit low in the back?
 
Re: CX500 Cream Cafe

Light Cage:

Well I've been seeing a few light cages pop up here, and I'm a trend humper so i decided to make my own. Usually people will have like a mesh or screen around the light, but I decided to just run parallel bars up the light.

I got my metal from a shelve that I found in my closet! Just one of the benifets of cleaning up your sleeping quarters.

0307001513.jpg


So I cut out the metal that i would need and spent a lifetime trying to get the powder coat off of it. Seriously I bet I spent over an hour just getting the metal ready before any fabrication took place. But once i got the metal I first bent the 7" circle. I don't have a bender, but not having proper tools has never stopped me in the past. I bent it by using my hands, a vise, and a hammer.

Rough circle
0308001807.jpg


I held it like this and used a hammer to get it more circular.

0308001808.jpg


Then I bent some of the smaller metal to give the cage a con-vexed shape. Weld those suckers down and your good to go!

0308001953.jpg


I''ve since prepped it for powder coat, by filing down all the spatter, and hitting it with some coarse sandpaper. It didn't cost me anything, but it did take at least 4 hours(because I used recycled metal).
 
Re: CX500 Cream Cafe

Ever get the rest of that liner out? Acetone can be used to dissolve some tank liners...
 
Re: CX500 Cream Cafe

I am soooo far behind on updates! Spring break with no job is a very productive time of year!

Tank:

Its all clean and sparkly in the inside! I don't have any pics since it is the inside of a tank, But finally after many many weeks of work the inside is done.
Few things that didn't go as planned:

1. I dropped the tank while shaking around the metal ready before lining the tank. This caused a big dent that i had my buddy help me take out. He used a stud gun, and ripped a hole in the metal! No worries though because he welded it back up and we pressure tested it for holes.
2. I put por-15 on the gas cap, and the outer lip of the filler hole, a few bubbles formed in the por-15 (probably because i didn't use metal ready there (i did on the inside but not the cap or outer lip.) The raised surface cause by the bubbles made it so the cap wouldn't seal right and gas spilled out on the first test mile. I have scrapped off the raised surfaces and it should be fine now.

Out side of the tank was completely de-rusted and stripped of paint. It took me over three hours to do it all but i got it completely done.

I have done the filler, sand, filler, sand, filler, sand, filler, sand, routine, and then did some glazing putty to get all the dents out.

This is the worse of the two sides.
0315001631.jpg


Then I coated it with some primer and could see many more places that need to be touched up. After more sanding, filling, sanding and primer the tank looks fine, and smooth. I then sprayed a "guide coat" I haven't done this before but it really helped me to see where the tank needs more help. I've yet to smooth it completly.

This is a guide coat before sanding.
0315001839.jpg

The sun blew it out, but its just gray primer with a mist of black primer over it. A pretty niffty trick really.

I have mounted the new tank. I used a cx500D tank, my bike is a CX500C. All i had to do to make the tank fit was cut off about 2" of the back mounting tab, and drill a new whole.

This pic shows the tab after cutting.
0315001927a-1.jpg


I still need to order up some rubber to mount it with (back, and two circle pieces up front.), anyone have any good ideas on where to find some good rubber locally?

Seat:

My seat is here!!! I'm so excited. I got it from a guy that sells on ebay under the name neuxstone. I'm loving it so far. It is very tough plastic and looks great. I do wish is wasn't so wide, but its not bad considering its a universal piece. I would whole heatedly recommend his seats.

0316001349.jpg


Seat mounting:

Well i had the seat for about 7 minutes and then I took the cutting wheel to it! The front of the seat isn't like most others i gos down if that makes sense, instead of just ending with a harsh edge it has a 1'' lip. That lip had to come off to make it sit lower. Other than that the seat wasn't modded.

I needed to make a sub frame for the seat. I went down to my other grandpa's and grabbed an old road sign, my uncle used to steal them when he was a teenager haha.

Free metal!!!
0316001544.jpg


I cut out the sheet, and welded up a sub frame out of square tubing i got for $8
0316001558.jpg



Then i welded some thick washers to the square and drilled holes in the sheet metal and the seat pan to run bolts thru.

Here is is all taped together for a fitment test.
0316001644.jpg


I forgot to take pictures of the rest, I'll have to grab some in the next few days. Basically I ran bolts thru the seat, sheet metal, then rubber bushings, thru the washers on the sub frame and bolted all of that together.

Then I welded the mounting tabs off my stock seat to the new sub-frame.
0317001532.jpg


The tabs have nutserts in them. Thanks to this thread here >http://dotheton.com/index.php?topic=5846.270 for inspiring me to use them. They are pretty amazing, but a bit pricey.

Here is a side shot showing the nut sert

0317001532a.jpg


Here is how the subframe sits on the frame.
0317001555.jpg


As you can see I ran button head bolts thru the part of the frame I added and then into the nutserts. The front just rests on the frame. I only have two mounting points, and I think I should probably have three at least, so any ideas/ critiques are welcome. I read in the horse where a guy said you should be able to lift the entire bike your fabricated modification, and I want to build this bike with that sort of a mentality. I will note however that the seat so far (30 miles) is very sturdy.

Paint:

Well i thought I would be going on a road trip this weekend so I threw some black paint on the tank, and side panels. Took me about two minutes and wont stay like this. I have already had three people tell me they like the rattle can 2 minute black paint more than they like the ppg one week paint i had on it last year with the old seat. I think they're blind.

Here is it
0317001824.jpg



Questions:
Wher can I get some good rubber to mount the tank with? I know i know i can get stock replacments off ebay, but I'm hoping for some new rubber i can get from a store. Thoughts?

Also how the seat is mounted, what does everyone think about that?
 
Re: CX500 Cream Cafe

How could I forget to mention my clubmans?

Last year the throttle tube would turn properly, so in an act of stupidity i grinded off the powder coat and to much metal. After that the whole throttle assembly would twist when you gave it gas. It had to be fixed properly. Throttle cables replaced and a a new chunk of metal welded to the bars.

Here is the side in question
0311001842.jpg

complete with keystone can spacers haha.

Lopped off

0311001854.jpg


And new piece welded on

0311001922.jpg


Then i hit it with a coat of black spray bomb. When i pull the bike apart to paint I'll have these powder coated.
This whole week I've been working at least 8 hours a day on the bike. I have a few more updates to post soon, and a bunch of stuff left to do. Hopefully I can fix the wiring problem that has caused my gauge lights, blinker running lights up front, and brake/license plate light to go out. Then i can get it registered and shake it down.
 
man got to be honest... not feeling how the seat is mounted at all, has a weird angle to it, looks like a ball crusher, love the headlight guard!
 
YA man... That guard is killer. Very cool idea! Im on the fence on the seat. A more level mount would be more comfortable for ya in the end (no pun intended). Everything else is looking good though! Keep up with the updates!
 
Yeah, I am with them on the seat buddy, I say trim the back a touch to the shape of the rear fender so it sits over it real tight. If there is other stuff under the actual seat area, you can cut holes in it to let them through, then just build a seat pan for your padding to go over it. I would have to see more pics to really offer more advice. Looking good though. It is not really that bad, but worth trying to fit more level, as that would really make it look better.
 
I guess by now you know that we all think the seat needs to be level. Looks good and can def work but I would try to get it level too. Like twisted said cut the back of the fender out a little then lower the rear of your subframe. I love the headlight guard. I am def gonna do one on my next bike. Keep it up.
 
Wow and I was worried about the line of my tank :p haha.

Leveling off the seat shouldn't be to hard. My plan is to pound a small relief into the rear fender and if necessary put spacers between the seat pan and sub frame. I wish i could get it done tonight but I had an opportunity to make some money today and tomorrow, plus i have a bunch of backed up homework so the bike will have to wait till the weekend.

Thanks for all the constructive criticism! Most people are to afraid to give an honest opinion so when people tell it like it is I appreciate it. Its one of the main reasons I join this board really.

Stay tuned for fixed seat pics soon!
 
looking forward to seeing how your seat turns out. CX's are a pain when it comes to getting the right kind of look on the seat (that damn dip in the frame)! I just got mine mocked up and it wasn't easy to conceptualize. Good luck on yours!
 
You must log in or register to reply here.

DTT Light or Dark

  • DTT Light
    • www.jadusmotorcycleparts.com
    www.lostapostle.ca/
    www.sparckmoto.com

    Spread the Love

    Back
    Top Bottom