1983 XV500 Cafe Racer

Karlloss

Been Around the Block
Did some work on the seat pan today.




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Karlloss

Been Around the Block
Made the seat mounting spars today. Used some box section and sliced it in half, then shaped it to fit using a end mill the same diameter as the subframe tube.




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Karlloss

Been Around the Block
I’ve decided to remodel the swing arm.


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Karlloss

Been Around the Block
I’ve cut the ‘joining rib’ off and I’m going to weld in a flat piece to tidy it up.


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Karlloss

Been Around the Block
I’ve remodelled the lower shock mount on the swing arm and also manufactured a new lower shock end/mount.




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SONICJK

Reminds me of...me No, I'm sure of it. I hate him
Awesome work.
How does the new shock mount attach to the shock shaft?
 

Karlloss

Been Around the Block
The original was spot welded on. I was going to cross drill through the mount and the shaft and use a roll pin. However I’ve now drilled and tapped the shaft and used a screw up through the centre which is accessed by taking out the rose joint. I’ll post a picture later.


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Karlloss

Been Around the Block
It’s been a while since I’ve posted. Life seems to get in the way of my project. I was hoping to have had it finished years ago, but hey there it is.

I’ve been dealing with something different recently, I have just bought a Honda CRF250RE for a bit of green-lane, enduro and MX riding. However the speedo/odometer has a broken mounting peg, which the previous owner has repaired.
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Karlloss

Been Around the Block
To remedy this I opted to make some new mounting pegs, I thought that making a socket to fit over that I could clue in place.
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Karlloss

Been Around the Block
I decided to use acetal, but then realised about nothing is able to glue this stuff, so I then tried nylon 6.6. Nylon can be glued, but the bond isn’t that strong. So I thought about another way to fix the problem.


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Karlloss

Been Around the Block
Rather than have a socket and gluing it. I’m going to use an insert with a screw thread and screw and glue the insert/mounting peg into the housing.
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Karlloss

Been Around the Block
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.
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Karlloss

Been Around the Block
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.
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