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  1. Karlloss

    1983 XV500 Cafe Racer

    Bit more progress today. Sent from my iPhone using DO THE TON
  2. Karlloss

    1983 XV500 Cafe Racer

    Managed to find some more time today. If only I didn’t have to work for a living, my project would have been finished years ago! Sent from my iPhone using DO THE TON
  3. Karlloss

    1983 XV500 Cafe Racer

    Sent from my iPhone using Tapatalk
  4. Karlloss

    1983 XV500 Cafe Racer

    Managed to find some time today to fabricate the rear exhaust header. I’ve had to modify the retaining clamp, as it’s a pig to fit due to the complex bends. Still all a work in progress. Sent from my iPhone using Tapatalk
  5. Karlloss

    1983 XV500 Cafe Racer

    Thanks Sent from my iPhone using Tapatalk
  6. Karlloss

    1983 XV500 Cafe Racer

    Thanks. Sent from my iPhone using DO THE TON
  7. Karlloss

    1983 XV500 Cafe Racer

    Completed some more fabrication on the exhaust today. Sent from my iPhone using DO THE TON
  8. Karlloss

    1983 XV500 Cafe Racer

    I’m not sure how to complete the exhaust yet. I was thinking of a low level exhaust, but now I’m going for a high level. Not decided if I’ll go for a 2-1 or singles yet. Sent from my iPhone using DO THE TON
  9. Karlloss

    1983 XV500 Cafe Racer

    Thanks. I cannot claim the credit though, I saw a similar set-up elsewhere. Sent from my iPhone using DO THE TON
  10. Karlloss

    1983 XV500 Cafe Racer

    Unfortunately she didn’t have one, so had to buy one. Sent from my iPhone using DO THE TON
  11. Karlloss

    1983 XV500 Cafe Racer

    Started on the exhaust this weekend. I’ve made it from stainless, although I’m that happy with my welds, might have to re-do the whole thing, but we’ll see. Sent from my iPhone using DO THE TON
  12. Karlloss

    1983 XV500 Cafe Racer

    I managed to make a very rudimentary cutting table today, excuse the crudeness of the set up, once I get time I’ll make a better one. However it cut the foam a treat including doing very fine trimming cuts. Sent from my iPhone using DO THE TON
  13. Karlloss

    1983 XV500 Cafe Racer

    To cut the foam for the seat, I’m making a cutting table and using an electric carving knife as the cutting blade. The reason for making a table was that my practice cut freehand wasn’t good enough. This is the mounting bracket for the knife and a blade guide as there is a lot of flex in the...
  14. Karlloss

    1983 XV500 Cafe Racer

    It’s been a long time since I’ve done any work on the bike. However I found some time to get into the garage and do a bit today. Made the brackets to hold the seat pan in place. I’m now making a cutting table to cut the seat foam, as free-hand cutting isn’t going to work. Sent from my iPhone...
  15. Karlloss

    Project Panther - Yamaha XS850

    Great work. Especially the TIG work, I'm looking to make an exhaust the same way for my project, although my project has stalled a bit!
  16. Karlloss

    1983 XV500 Cafe Racer

    When I rough measured the spacer, I measured it at 7mm. As it was a rough measurement, I decided to machine it to 8mm, to be on the safe side knowing that I can machine it further if needed. I’ve fitted it up solid, guess what I need to take 1mm off the spacer. Maybe my rough measurements aren’t...
  17. Karlloss

    1983 XV500 Cafe Racer

    I made a jig to hold the wheel in position as I needed to machine the disc register down to be able to accept the spacer and due to the diameter of the wheel I was able to mount it in the mill, but as my mill has a tilting head, I was able to improvise. Sent from my iPhone using DO THE TON
  18. Karlloss

    1983 XV500 Cafe Racer

    You’d think with lockdown I’d have finished my build by now. Unfortunately I had major surgery to my arm and shoulder in March, just before lockdown, which meant I’ve had loads of time, but not able to use my arm, until last weekend. I’ve made the front wheel spacers to fit into the bearings on...
  19. Karlloss

    1983 XV500 Cafe Racer

    I’ve used epoxy glue to act as a waterproof barrier and to lock the plugs into place. The threads are sufficient but the glue will help the joint become permanent. Sent from my iPhone using DO THE TON
  20. Karlloss

    1983 XV500 Cafe Racer

    I started to make the plugs however using M6 was my folly as I managed to snap the threaded section off, so I’ve opted for M8 to ensure there is more meat on the plug threads. Sent from my iPhone using DO THE TON
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