CJ360T Cafe Project (UPDATED Pics, getting close)

H

HelthInsXpert

Active Member
I've always had the idea of building a cafe racer so here's my first attempt. I bought this non-running CJ360T for $305 and here's the progress so far.

Ordered a CB200 tank, stripped the frame down and plan to sandblast and powdercoat on Saturday. The bike needs a lot of work but the motor is very clean and should run great.

Here it is the day I picked it up:
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This is where I got after 2hrs of work:
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Motor:
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(any tips on how to get this oil filter out?)

Frame only, ready for sandblasting:
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Cleaned up the front hub last night and polished the brake linkage:
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Polished
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Ok, skip ahead a bit and here we are today:

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ROLLING CHASSIS!!!

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With the tail section I'm working on. Still needs the second coat of body filler to be sanded down, and I'm cutting the seat shorter a bit, but it doesn't look bad.

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Polished up the front hub really well. I'm quite happy with the results.

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Clipons loosely installed.

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Another shot of the tail.
 
Re: CJ360T Cafe Project (Columbus, GA)

Cleaned up the carbs with stripper and soda blaster. Had to get a new diaphram to replace one that was torn.

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Re: CJ360T Cafe Project (Columbus, GA)

PM replied to.

Let me know if you need any parts...I might have them for you. Although, if you're going the cafe route, you probably won't need any of the stuff I have available. :)
 
Re: CJ360T Cafe Project (Columbus, GA)

So the frame is now sandblasted and I'm working on filling some of the pits. Should have some paint on very soon. CB200 tank arrived yesterday and I was disappointed to find that the 'Kreem' job that had been performed was TERRIBLE. It's all flaking off and the whole tank needs to be re-done internally. I heard POR-15 works better so I ordered that.

Still trying to figure out what I want to do for a seat design. I feel like I might want to retain some the original CJ360 design and keep the tail section. But I'm also working on a foam mockup to fiberglass over for a more traditional looking Cafe Seat. Here are a few pics.

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Re: CJ360T Cafe Project (Columbus, GA)

fwiw i really like the cj tail with the 200 tank... i think the straight lines of the tank work well with the stock tail. the rounded cafe tail has already been done a million times, but the cj tail with the 200 tank gives your bike a really unique almost dunstall look!
but either way, it's lookin' good man!
 
Re: CJ360T Cafe Project (Columbus, GA)

Thanks guys, I think I may keep the CJ tail if I can find a way to mount it. Or possible make a replica in fiberglass integrated into the seat. We'll see how that goes. But I agree, the CJ tail look sharp.
 
Re: CJ360T Cafe Project (Columbus, GA)

I agree with Overdarft. That seat hump is a pretty good match for the tank.
 
Re: CJ360T Cafe Project (Columbus, GA)

It should be possible to extend base of seat and bolt CJ tail through it.
The big circlip has to come out to remove cover, then you use a case bolt in center to draw it out.
You need a special peg spanner to remove oil filter cup but they are pretty easy to cut out of an old socket with an angle grinder (or you could buy the special tool, about $12.00 at various places, actually more expensive on eBay ($20.00 including P&P)
 
Re: CJ360T Cafe Project (Columbus, GA)

Yeah, I like that squarish tail and that tank. It flows great. Great to see another GA member. Wish there were more, and wish they were around ATL! So you an Auburn or UGA fan? :D
 
Re: CJ360T Cafe Project (Columbus, GA)

03rangerxlt said:
Yeah, I like that squarish tail and that tank. It flows great. Great to see another GA member. Wish there were more, and wish they were around ATL! So you an Auburn or UGA fan? :D
Click to expand...

Friend from Marietta told me there are 'gangs' of cafe's around Atlanta? (at least, 2 yrs ago)
I know there are a lot of 'biker' pubs
 
Re: CJ360T Cafe Project (Columbus, GA)

03rangerxlt said:
Yeah, I like that squarish tail and that tank. It flows great. Great to see another GA member. Wish there were more, and wish they were around ATL! So you an Auburn or UGA fan? :D
Click to expand...

I'm here as well. Haven't started building my bike up yet though so I guess I might as well be in China.
 
Re: CJ360T Cafe Project (Columbus, GA)

Sorry about the lack of time between posts, just have had a hard time getting parts in like I need. And figuring out how to integrate the stock tail section onto a useable seat is giving me fits. Should I just make a fiberglass seat pan and bolt the fairing to the back?

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Anyway, here's a few pics of progress so far.

I have powdercoated the fork lowers, and triple tree satin black. (need to get pics of that). Mounted my clip ons and everything looks great up front.

Polished (kinda) the hubs, and relaced the wheels. I'm waiting on tires to come in and will take them to get trued and mounted.

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Engine is totally apart and waiting on standard piston rings to get that back together.

Ordered XS 650 Coils at the suggestion of someone on this forum. Got those yesterday and I hope they will work alright. They look great.

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Still need to find a CB200 Tank pad/cover. Who knew those would be so difficult to find.

Got my Brass swingarm bushings. They are really good looking, I wish they weren't totally hidden!

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Got the exhaust cut down to something close to what I want. I would really like to get CL360 high mounts on there, but I havn't found any for cheap yet.

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Re: CJ360T Cafe Project (Front end, fiberglass tail started, wheels laced)

Got a smaller TruGel battery to replace the old one. I think this may fit under my seat.
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Got the front end put together.
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And finally cleaned up the garage.

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Re: CJ360T Cafe Project (Columbus, GA)

Hell yes, another GA member! Bike is looking solid so far!


crazypj said:
Friend from Marietta told me there are 'gangs' of cafe's around Atlanta? (at least, 2 yrs ago)
I know there are a lot of 'biker' pubs
Click to expand...

I don't know if I would consider kids who shop at urban outfitters, rock skinny jeans, smoke newport lights in a box, drink schlitz because PBR is too mainstream now, and hate their parents to be a 'gang' of any kind.... ;D

In all seriousness, theres a decent contingent of old bikes around here but I haven't seen alot of Vintage group rides. I know AMR is trying to get one started up but as far as Atlanta being a cafe-hub....I would think the cafe riders would be greatly outnumbered by all the Busa riders that fly up and down 75....
 
Re: CJ360T Cafe Project (updated pics, wheels, front end, seat)

Yeah, not a lot of folks in my neck of the woods. Atlanta is about 1.5hrs away.
 
Re: CJ360T Cafe Project (updated pics, wheels, front end, seat)

There is a 'chopper' shop next to Blue Riband Cycles in Atlanta that built a cafe style bike for magazine when I was there a few years ago. (don't remember of shop but it is quite well known)
I didn't see any 'gangs of cafe bikes' had to take Nate's word for it
I made my own high level exhaust for CJ250 (bored to 391cc ;D )
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It's mostly a nasty CB400 front, cut, shortened and collector turned sideways with 2litre Ford center expansion box as a silencer.
The pipe that goes over the car axle got cut and welded to fit inside frame.
It's done at least 3,000+miles (including being on British TV)
 
Re: CJ360T Cafe Project (ROLLING CHASSIS!!) Finally

Got some new pics up on page 1. Finally have a rolling chassis.

Brakes are in, tires mounted, hubs polished. Front end has clipons installed. Currently working on getting the tail looking good and making sure it's strong enough. Waiting on piston rings to get the motor back together. Once I get the tail looking good I'll be painting the tail, tank, and frame.

Still need to figure out what I'm going to do for rearsets. If anyone knows how to replace the speedometer cable I really need some help. There's a really small pin inside the front hub that I can't get out.
 
Re: CJ360T Cafe Project (Motor in, frame painted, Updates)

Well after about 2 weeks working on the motor and waiting on parts/tools to come in I think I've got everything buttoned up. We'll see in a few days if I got it right. Any tips or mistakes people usually make?

Today my Mikuni Carbs came in from Dime City Cycles, along with the Loaded Gun rearsets I ordered. Got the Carbs on and the motor mounted in the frame. (only to realize I forgot to drop the cam chain tensioners in, so we'll be pulling the motor back out tomorrow.

I fitted up the ignition coils I ordered from Mike's XS tonight. Anyone have any feedback or did I even get the right ones?
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So here are a few pics from today:

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Re: CJ360T Cafe Project (ROLLING CHASSIS!!) Finally

HelthInsXpert said:
I fitted up the ignition coils I ordered from Mike's XS tonight. Anyone have any feedback or did I even get the right ones?
Click to expand...
fwiw those are the exact ones i got for my cb350 and they work great!
 
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