Guzzi Cali Cafe - Build Thread

Perter

New Member
Nice video, if I did the same in my garage, I would probably stumble over s&%# on the floor and crash the camera ;)
 

Bevelheadmhr

Active Member
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Perter said:
Nice video, if I did the same in my garage, I would probably stumble over s&%# on the floor and crash the camera ;)
Same here lol... what you don't see is all the junk I took out and left outside while making the vid, when I finished, it all had to go back in again.
 

CarbsAndCylinders

Careful With That Axe Eugene
Bevelheadmhr said:
Same here lol... what you don't see is all the junk I took out and left outside while making the vid, when I finished, it all had to go back in again.
Ha ha, maybe you can give me a hand at that>
 

Bevelheadmhr

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Since you liked the walk around our Spares Bike project last week, I made another video of our main project where all the spare parts came from.. our Nitro bike..

Warning.. it goes on for 27 minutes.. but if you like bike engineering and want to see what can be achieved in a small shed and a shoestring budget, it may be worth your time, we have a laugh too

https://youtu.be/Thyjo6FA6NE
 

Bevelheadmhr

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Finally got confirmation from the chromers that my parts are ready for collection, they close at 3 on Fridays (lazy sods :lol: ) so to avoid the M6 Friday afternoon car park, I'll go in the morning. Its only a small step forward, but at least its progress.

Also been thinking about the paintjob, its going to be red, with gold detailing to match the gold Guzzi decals. Wasn't sure about leaving the knee cut outs unpainted, and that's still the case, but having seen this Guzzi recently which has a similar alloy tank to mine, I may go with that option, what do you think??
 

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Bevelheadmhr

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Yesterday I collected the parts from the chromers, very pleased with the results, and it wasn't long before those parts were fitted back on the Guzzi. I was unsure if chroming the headlight was a good idea or not, but now its done I think I made the right decision.

There has also been progress on a couple of billet parts I'm making, not as much as I'd like, but its a start. Since I'm getting the hang of making videos now, here's a couple of vids that show you what I'm talking about..

https://youtu.be/Usa9XrhSqq0

and

https://youtu.be/svDXSaWxT_U
 

adventurco

Nick Ol' Eye
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Looking good. I do like the unpainted knee dents on the black tank, but red may not give enough contrast for it to have the same effect. If the tank is full red, maybe a black or gold pinstripe around the knee dent would create a good bit of contrast. You could always just paint the dents gold instead


Sent from my iPhone using DO THE TON
 

Bevelheadmhr

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adventurco said:
Looking good. I do like the unpainted knee dents on the black tank, but red may not give enough contrast for it to have the same effect. If the tank is full red, maybe a black or gold pinstripe around the knee dent would create a good bit of contrast. You could always just paint the dents gold instead


Sent from my iPhone using DO THE TON
You may be right about red not having enough contrast against the polished alloy knee cut outs if they are left unpainted, unlike a black colour scheme. In fact, I made a video about it lol..

Well, this week has been a good one for the Guzzi, its new billet fork brace has been machined and fits fine, though it still needs more work to make it look better. That all happened today, and I filmed the steps of the fork brace being made, which is now on youtube. Meanwhile my new billet alternator cover has been started too.

The new stainless spindles (for which I've been waiting months) have been machined on a CNC lathe, and now the machine shop have written the program, they could churn out hundreds a week... pity mine are not standard, I designed in a couple of extra features. By chance I happen to be passing by on the afternoon they were being made, so I got to see the first one being made, got a video of it too, though I wont post that until next week when I collect all those parts.

Our other projects are making good progress too... may as well make the most of it while it lasts lol.

Its been a busy week for me, as yesterday I spent the day in my local Dynojet dyno, filming the process of a bike being given a power run. Sam, the dyno operator is a racer, just back from the TT, he crashed during practice, fractured his pelvis but still raced the following week, they're all mad !
 

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Bevelheadmhr

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I took the new fork brace home for a test fitting, and thankfully it did fit ok, but it definitely needs more work to make it fit into the style of the front end, and particularly the yokes. As it is now, the brace is too angular and plain.

The next day I collected the new alternator cover, which has been machined from a solid piece of billet alloy. Its also not finished yet, but I took it home to check it fitted onto the engine, before anymore work was done on it. At first it didn't fit, as I' measured the diameter of the alternator outer case wrong, but with a bit of filing, the cover went on and its mounting holes aligned with those of the engine case, which was a relief. That cover will be going back to Jeff's workshop next week for more machining, this time on the outside to make it look better.

And there's a couple of videos of all this on Youtube too, an one of my new wheel spindles being machined on a CNC lathe.. :)
 

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Bevelheadmhr

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The machining on the new fork brace is finally complete (underside machined, edges bevelled and centre hollowed), as are the new one off stainless spindles. The billet alternator cover is due for its final machining in the next couple of days, that's mainly to make it look better. In the meantime I've been prepping the brace for polishing by using wet n dry sandpaper in finer an finer grades to remove all the marks and scratches from its surface. That'll be going to a trip on the polishing mop this weekend, along with the alternator cover. Not looking forward to that, as its a filthy job, I always end up looking like I've done a shift down a coal mine, despite wearing protection...
 

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Bevelheadmhr

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Finally, finally the one off fork brace and alternator cover are done and fitted to the bike. Spent this afternoon polishing these two pieces on the polishing mop, at the end of which they looked ok, not exactly show quality, but good enough for me on a road bike..

While that was happening, we made a short video again, this time showing how we use the polishing mop..

https://youtu.be/RrAEDVnvSdM
 

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Bevelheadmhr

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This week I finally decided where the new lithium battery was going to live on the bike. I made a tray in cardboard, then took it to Geoff the welders workshop, where he made it in stainless for me. I made video of the process, and had a look around his workshop... converted from a 17th century farm building, most of his equipment is pre war too...

https://youtu.be/JfUj5Zn41iA
 

Bevelheadmhr

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The new spokes and Borrani rims arrived this week, it didn't take long to get them laced up and trued. Though I did hit a problem with the rear wheel, as the drive side of the hub didn't have a bearing (its part of the bevel box on the bike), which meant it wouldn't fit on my trusty wheel stand. Had to make an adaptor bush which worked surprisingly well. I ordered Morad alloy flanged rims, but they were out of stock, and would be for a long time, so got the equivalent Borranis instead. They are ok, but not quite as nice as the Morads.

Next week I'll get the tyres fitted and balanced, then fingers crossed the bike will be on its wheels at last.

I took a couple of vids of the process, which took longer to make than building the wheels.. think I need a faster laptop... anyway here they are..

https://youtu.be/4KXXeWj8p2Q

https://youtu.be/rVhruA1_Rdk
 

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Bevelheadmhr

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Got the tyres fitted to the wheels, had a small problem as the bike shop couldn't balance the wheels, because the flanged Borrani rims left too little room to fit the standard stick on wheel weights. Something to sort out another day. Back home, the wheels went on ok, using my new stainless spindles and stainless wheel spacers, calipers back on, seat and tank back on, not so easy in a confined space on the hottest day of the year here in sunny England. I was keen to get the wheels back on the bike so I could roll it out majestically into the summer sunshine.

But it wasn't to be, the old Guzzi didn't want to budge... maybe the new pads are sticking, maybe its still in gear or maybe the clutch plates are sticking after so long being unused?? Well, the front wheel wasn't the culprit, and with no clutch cable fitted it wasn't possible to get much further. Better fit that cable then, I would've done if it was where I thought it was. Looked everywhere for the damn thing with no joy. I'm sure its with some other Guzzi spares that I put somewhere for 'safe keeping', a couple of years ago, an now I have no idea where that may be. I need to order a few more parts, so I'll order a new cable too. Its not a problem ,as the old cable is more than 25 years old, so replacing it is a good idea in any case. Though it is frustrating, as I'd hoped to have a look at the bike from more than a few feet away at last.
 

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