1983 XV500 Cafe Racer

Karlloss

Been Around the Block
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.
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Karlloss

Been Around the Block
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.
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Karlloss

Been Around the Block
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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.


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Karlloss

Been Around the Block
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.
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Karlloss

Been Around the Block
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.
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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

Been Around the Block
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.
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Karlloss

Been Around the Block
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.
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