Kawi ZRX Cafe Project

[roadracer41]

To start off, I'm a 16 year old sophmore in high school in Alabama. I've always liked cafe bikes, and now I have a chance to build a radical one. This project will be a cafe racer built around a 2000 Kawasaki ZRX 1100. Pulled the frame down from storage March 18, and the goal for completion is the Barber Vintage Festival in October.
Day 1:
Ground off unnecessary tabs to allow for a Lossa seat. The back part of the frame will be cut off and a round hoop will be welded in place.
Also got Bondo on the gas tank to smooth out some dips in the metal.

Colin

 

[Maritime]

Re: New Guy with a Major Project

Welcome, nice start, there are some really stand up members from Bama and a bunch of DTT'rs from around the world hit Barber every year. Glad to see a highschool kid who can get hands on! There is hope yet that bikes won't die off with the old folks.

Cheers,

Maritime.

 

[Tim]

Re: New Guy with a Major Project

Good stuff! Looking forward to seeing you and the bike at Barber's. Just under 7 months to go!

 

[cyclefreak]

Re: New Guy with a Major Project

Welcome to the site. So what part of Bama are you from?

 

[roadracer41]

Re: New Guy with a Major Project

Welcome to the site. So what part of Bama are you from?

Huntsville

Day two:
Finished grinding the tabs off the frame. There was one on the top on each side of the frame and two others on each side.
Sanded down the Bondo on the sides of the tank to get it ready for another coat of primer.
Ordered a seat hoop to connect around the back of the frame since we're going to cut it off just behind the seat support going across the frame.
Also paid for clip-ons and a cafe-inspired seat from Lossa Engineering.

 

[roadracer41]

New Guy with a Major Project

Had a week off for spring break, do no progress until today.
Filled in some dents in the tank and put a coat of primer on it. We also had to put some body filler in a few dents in the frame to smooth it out.
Also, started designing some custom aluminum parts to send to the machine shop.

 

[Ringo]

Re: New Guy with a Major Project

Welcome aboard. I'm not following that last pic. What are we looking at?

 

[Nojokirk 75cl360]

Re: New Guy with a Major Project

im on board dude! Im also 16 and also doing a cafe/bobber project. Ill be on the watch.

 

[roadracer41]

New Guy with a Major Project

Welcome aboard. I'm not following that last pic. What are we looking at?

The left side of the frame where we cut mounting tabs off. There were several small dents in the metal, and used Bondo body putty to fill them in so the frame tube will look and feel smooth after paint.

 

[Really?]

Re: New Guy with a Major Project

One of the old folk subscribed to see what the youngin' can do.

 

[Ringo]

Re: New Guy with a Major Project

One of the old folk subscribed to see what the youngin' can do.

Would you be the same Really? from sohc4? Glad to see you over here, if so!

 

[Really?]

Re: New Guy with a Major Project

Yessir, that be I. Interesting place here. They will cafe style anything. I am enjoying it.

 

[roadracer41]

New Guy with a Major Project

Haven't done a lot on the bike lately, but have been working on some stuff in the machine shop. The pic is what is going to become the radiator overflow bottle. It's going to be mounted underneath the seat. Also have my brother working in boxing in the front section of the swing arm to both strengthen it and for the crankcase breather. Once we get the seat, we should be able to make some serious progress.

Colin.

 

[roadracer41]

New Guy with a Major Project

We can finally got the seat from Lossa Engineering, so we can start making some serious progress. We found out the frame is wider than the seat, so we've got some work I do on the back of the frame. We're also going to add some cross supports underneath the seat to eliminate the seat bending under the weight of the rider. Now, it's starting to look like a motorcycle.

Colin

 

[cklamer]

Re: New Guy with a Major Project

Welcome to the Ton from Huntsville Alabama.

Love the Barber Vintage Festival.

 

[beachcomber]

Re: New Guy with a Major Project

We can finally got the seat from Lossa Engineering, so we can start making some serious progress. We found out the frame is wider than the seat, so we've got some work I do on the back of the frame. We're also going to add some cross supports underneath the seat to eliminate the seat bending under the weight of the rider. Now, it's starting to look like a motorcycle.

Colin

Just an observtion - why not widen the seat - much simpler and the seat will flow into the rear of the tank batter ???

 

[Ringo]

Re: New Guy with a Major Project

I agree with TJ. Lot easier than modifying frame and playing with shock mounts.

 

[roadracer41]

Re: New Guy with a Major Project

Just an observtion - why not widen the seat - much simpler and the seat will flow into the rear of the tank batter ???

thanks for the suggestion. I'll look at it when I get out to the shop today.

 

[roadracer41]

New Guy with a Major Project

After looking at the frame today, I think what we're gonna do is cut te frame off behind the tape (left side of the tape) and angle a piece of chromoly tubing fro the end d the frame to the seat hoop. No fiddling with the shock mounts, and easier than messing with the fiberglass. The angled pieces represent the pieces to weld on. Thanks for the suggestions.

Colin

 

[VonYinzer]

Re: New Guy with a Major Project

Cool so far. Im watching.

A thought though...

You dont need super up close cell pics. Really tough to see... We can make out what youre doing with wider shots.

Anyhow, keep up the good work bud.