Guzzi Cali Cafe - Build Thread

Managed to get it rolled out the garage today, the problem was that the new brake pads and rebuilt discs were a bit 'sticky', should be ok with some miles under its wheels. Also spaced out the billet alt cover as it seems the alternator on mine isn't that reliable and doesn't like to get too hot, hence the spacers to let the cooling air in.

Removed the sump, cleaned it up, bead blasted it and now got I'll probably paint it, same colour as the bevel box.
 

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That looks good! What is the plan for mufflers? I have the same rear set bracket and I am looking for some upswept reverse cone mufflers in stainless or a upswept adapter in stainless. Can't seem to find that, only in chrome.


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Rusnak_322 said:
That looks good! What is the plan for mufflers? I have the same rear set bracket and I am looking for some upswept reverse cone mufflers in stainless or a upswept adapter in stainless. Can't seem to find that, only in chrome.


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I'll be getting LM4 stainless replica pipes for mine, from Armours here in the uk, less than half the price of chrome Lanfranconis..

here's the link https://www.armoursltd.co.uk/page/2/?s=moto+guzzi&post_type=product
 
That is just lovely. Absolutely what a bike should look like. Top job. Maybe a splash of red on the tank somewhere or a bit of silver on tail?
 
RR100 said:
That is just lovely. Absolutely what a bike should look like. Top job. Maybe a splash of red on the tank somewhere or a bit of silver on tail?
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The tank and seat will both be painted, probably red, still haven't decided on the details. This latest vid explains it better..

https://youtu.be/xkL0H2AX0j8
 
Will you sell it when finished or is it a keeper?

I looked yesterday for one here and seems 6K north to get a good runner, so now I will keep an eye out for that fire sale ;)
 
Tune-A-Fish said:
Will you sell it when finished or is it a keeper?

I looked yesterday for one here and seems 6K north to get a good runner, so now I will keep an eye out for that fire sale ;)
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I didn't build it to sell, if I did then it'd be finished long ago without most of the time consuming one off parts. I like to build and mess about with bikes, but I hate selling them, the problem with that is lack of space, I've run out, no more room for any new projects. Which is frustrating as I have a couple of big project ideas I'd like to take on next. Then again, I've got plans to mod and upgrade most of my other bikes when I have the time and/or the money. I do have a slight concern that the Guzzi will be too similar to my Norley, (both stripped down, alloy tanked, 1000cc pushrod V-twins..) and maybe I should only keep one? It'll probably take a few years of riding both, for me to choose :)
 
Bevelheadmhr said:
I didn't build it to sell, if I did then it'd be finished long ago without most of the time consuming one off parts. I like to build and mess about with bikes, but I hate selling them, the problem with that is lack of space, I've run out, no more room for any new projects. Which is frustrating as I have a couple of big project ideas I'd like to take on next. Then again, I've got plans to mod and upgrade most of my other bikes when I have the time and/or the money. I do have a slight concern that the Guzzi will be too similar to my Norley, (both stripped down, alloy tanked, 1000cc pushrod V-twins..) and maybe I should only keep one? It'll probably take a few years of riding both, for me to choose :)
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I am very sorry to hear about your concern, the possibility of having so many beautiful bikes so that two may be too similar if a serious issue. I am sure that there are some kind individuals here who would be more than happy to help you with this, including me. :)
 
CarbsAndCylinders said:
I am very sorry to hear about your concern, the possibility of having so many beautiful bikes so that two may be too similar if a serious issue. I am sure that there are some kind individuals here who would be more than happy to help you with this, including me. :)
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You concern has truly touched my heart.. ;)
 
What a beauty enjoying the sunlight after a long period in the shed.

What's the schedule, do you expect to get it running this season?
 
Not sure about having a schedule, but yes I want to get it running next month, if not completely finished by then. The paint will be the last step of the build.
 
A few more parts arrived in the post this week... indicators, cables and a small LED rear light.. maybe a bit too small? It'll be getting a billet cover to bulk it up a bit and to match the rest of the bike. Also fitted the freshly painted sump and filled it with fluids, though had a brain fade and overfilled the transmission with the engine oil... duh! Oh well, helped flush it out I guess.

Here's the latest two vids showing some of the progress this week..

https://youtu.be/O3vWBnLQk6I

https://youtu.be/axQEhhSVVWU
 
Finally decided to go for the obvious answer for the front indicators.. drilled the headlamp brackets, so it pretty much copies how Guzzi did it on the original bike. Next, turns out my newly bought throttle cable.. had to get a shorter one for the clip ons.. doesn't fit the Tommaselli throttle, so ordered a kit from Venhill and I'll diy. Got a similar problem with the choke, as the LH handlebar clamp/switch gear is damaged, which also holds the choke lever. The solution is to do away with said lever and cables / splinter and retro fit plunger chokes to the Carb tops. Those are £15 each, which isn't too bad in the scheme of things.

Yesterday the stainless LM silencers arrived from Keihan, went for the earlier LM1/2 style rather than the bulkier LM4/5 design. They look well made and fit ok, except for the mounting brackets not matching up with the Tarrozzi rearsets. Not really a surprise, so that's something else to sort out.

I'd originally wanted to something similar from Armours, but despite Emails and many phone calls last week, they never replied or picked up the phone. So went with the slightly more expensive Keihans, ordered them on Tuesday, arrived today, two days later.
 

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its starting to come together. looking good!
 
Having wasted hours trying to make a bracket to mount the silencers to the Tarozzi rearsets look anything but crap, I gave up and ordered a LeMans 1 H pipe to replace the battered original on the bike. Cost me £110 from Keihan, but it allows the silencers to move forward just enough to line up the silencer mount with the rearset mount. Looks much better too.

Cant make a start on the wiring yet, as I'm still waiting for the single fire coil I ordered last week to arrive. Though I am finally happy with the rear light mount/cover, having machined it down for the third time this week.

The next big expense will be the paintwork, still haven't decided what colour / graphics its getting, I'll probably keep flip flopping between red or black/gold until the last moment. There's no rush now, given it wont be finished until the good weather has long gone this year.. Be good to get the Guzzi all done and dusted, as I have a new mini project I'd like to make a start on soon..
 

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Having problems with the carbs, the new throttle cable I bought doesn't fit the Tomaselli throttle.. the adjuster thread is different, and there isn't enough meat on the throttle housing to tap it out... sigh... Will have to make up a new one using a Venhill kit, which I've got. Making it the right length looks tricky given the 1 into 2 splitter the Guzzi uses.

Have a similar issue with the Choke cables, but in this case the handlebar casing which houses the choke lever is damaged and cant be used. So I spent £30 and bought a pair of replacement choke plungers which have the lever on the carb tops. Gets rid of three cables, the splitter and the handlebar lever too.


Finally finished the rear light and its mount, here's how it was made, along with getting the exhaust fitted correctly.

https://youtu.be/ZRnRCXc7K-8


And this is how it looks now. Still waiting on a couple of electrical parts, so cant make a start on the wiring loom yet. There's no rush now, as I want it needs to be finished by next spring. I'm still pondering what colour to paint it, red or black??? Cant decide.

If anyone can photoshop the tank the same colour as the seat, or both gloss black, I'd be v grateful.

I may have a go at painting it, though my past efforts while being ok, I've never managed to get that glass like finish I want.
 

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Made this little stem nut cover today, looks ok, though may make it a touch slimmer yet..
 

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Finally made a start on the paintwork, the seat unit was pretty easy (so far anyway), while I'm still working on the prep of the tank, really want to get the colour on and get it lacquered, but telling myself to do it right and not rush anything...

Here's progress so far today..

https://youtu.be/5Yl3r9g70a8
 
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