1983 XV500 Cafe Racer

[Karlloss]

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 the RD250 front wheel with the GSXR400 front axle. I’ve also mad a start on the spacer for the front disc.

Sent from my iPhone using DO THE TON

 

[Karlloss]

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

 

[Karlloss]

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 so rough after all.


Sent from my iPhone using DO THE TON

 

[Karlloss]

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 using DO THE TON

 

[Karlloss]

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 blades and this is an issue when cutting the closed cell foam I have.

 

[Karlloss]

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

 

[Karlloss]

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

 

[pidjones]

Nice foam cutter. I hope that isn't the wife's electric knife! (I bought mine on ebay)

 

[Jimbonaut]

Cutting table = genius

 

[Karlloss]

Nice foam cutter. I hope that isn't the wife's electric knife! (I bought mine on ebay)

Unfortunately she didn’t have one, so had to buy one.


Sent from my iPhone using DO THE TON

 

[Karlloss]

Cutting table = genius

Thanks. I cannot claim the credit though, I saw a similar set-up elsewhere.


Sent from my iPhone using DO THE TON

 

[JadusMotorcycleParts]

As others have said, awesome cutting table I am really looking forward to seeing where you go with the exhaust as well! I will likely be trying something similar for the XV535. I would like to route the headers that way to equal lengths and have the possibility to run either open pipes with baffles, or run an adapter to a 2-1 joint to a silencer - to gain some scavenging benefits as well.

 

[Karlloss]

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

 

[Karlloss]

Completed some more fabrication on the exhaust today.

Sent from my iPhone using DO THE TON

 

[briandk]

That exhaust header is shaping up very nicely. Love the machine work.

 

[Karlloss]

That exhaust header is shaping up very nicely. Love the machine work.

Thanks.


Sent from my iPhone using DO THE TON

 

[LKS]

Impressive work!

 

[Karlloss]

Impressive work!

Thanks


Sent from my iPhone using Tapatalk

 

[Karlloss]

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

 

[Karlloss]

Sent from my iPhone using Tapatalk