XS400 cafe build

sandmanred

Member
Fender back from powder coating. It's a candy over brushed aluminum. It looks great, the pics don't show the depth or the brushed texture underneath. Still not 100% committed as the tank may just not be good enough for a shiny finish without some bondo. Rattled canned the brackets for now just so I could see it put together. And got a side panel tacked in place.







 

sandmanred

Member
A bit of re-shaping on the set and a new cover. Clamp on walking foot on sewing machine helps but I'm guessing still not quite like a true walking foot machine. Quilt top stitch came out okay but still a little inconsistent on perimeter stitch but better than the last one. It definitely comes out smoother when you just glue the perimeter up under the pan, the last one I glued the whole thing down and it makes the seams show up a lot worse and telegraphed through any defects in the foam layer.









 

adventurco

Nick Ol' Eye
DTT BOTM WINNER
That came out great, nice work. I've wanted to have a go at sewing my own seat covers but don't have access to the proper machine.
 

sandmanred

Member
advCo said:
That came out great, nice work. I've wanted to have a go at sewing my own seat covers but don't have access to the proper machine.
Thanks. This one was done with an old Bernina that my wife bought at an estate sale for $9. It's not an industrial machine but pretty heavy duty. I added a walking foot attachment that seems to help too.
 

sandmanred

Member
The butt end of the left muffler fell out today so I'm going to make a go at new mufflers. A buddy and I built a slip roller for the cones. I'd hoped it would handle 18 gage but it looks like it will only do 20 gage in stainless. So far I have one cone.





 

trek97

Active Member
DTT BOTM WINNER
This is a really neat build. Your metal skills blow me away. Ive made a couple seat covers, and yours is amazing. Really cool stuff 8)
 

sandmanred

Member
trek97 said:
This is a really neat build. Your metal skills blow me away. Ive made a couple seat covers, and yours is amazing. Really cool stuff 8)
Thanks for taking time to look and the comments!
 

sandmanred

Member
More progress on exhaust. Still a few mods needed on the slip roll but it worked pretty good. Long cones were not too round before capping so I stuffed them into a round hole as I tapped the end cap in, worked as a nice secure holder too. The baffles are removable for tuning. A short reverse cone will somewhat hide the baffle but still allow access for removal.













 

sandmanred

Member
Not as far as I hoped to get today. Ran out of argon :mad:. Ran to get more before supplier closed. Got home, hooked up and found it's not argon though it is labelled :mad: :mad:. Too late to get back to supplier. :mad: :mad: :mad: Borrow some from a friend. :)

I did get them installed and a quick test run but too late for finished pics.



 

sandmanred

Member
Final polish.

One short ride last night. Definitely louder than stock. Pulled one plug and looks nice and tan. A little rumbling on decel but no backfires. Time for some more miles.



 

sandmanred

Member
Going to take one more run at the seat cover and start tear down for paint and powder. I picked up a new sewing machine that handles much heavier thread than what I had before. Going with black vinyl and a red top stitch the match the red that the tank and front fender will be. Top two pics show laying out the stitch lines for the quilted section of the seat. The front fender is already powder coated candy red over brushed aluminum. Rims to be gold and frame gloss black.

Any thoughts on the side cover color? I was thinking the same red as the tank but it's also been suggested to go black like the frame.





 

sandmanred

Member
I'm all torn down for paint and powder coating. The red on the fender goes on the tank and side covers, gloss black frame and gold rims. Tank gets some gold graphics to tie in the rims.

Here are the rims underway. Prime, followed by gold base and 2k gloss top coat. First time using rattle can 2k top coat. I'm impressed with the gloss and how it wets out. We'll see how it holds up.







 

sandmanred

Member
Waiting on powder coated parts. All my painting of little bits and bobs is done. Almost everything is de-greased. Tires remounted. Taking another run at the seat cover with bigger topstitching. And then hopefully start re-assembling sometime next week.

 

sandmanred

Member
Waiting on tank and side covers from powder coating. Tank and side covers will be the same red as the fender. Exhaust wrap on headers is next. Along with the latest seat cover attempt.

 

sandmanred

Member
Header wrap in place. I hate putting that stuff on but it dresses up my beat up headers. Ties in nice with the gold on the rims I think?

 

sandmanred

Member
Thanks!

Still waiting on tank and covers, should be soon. Put on the latest seat cover today. This one has a much larger top stitch and few less defects than the last one ;-) The white marking in the close up needs to be wiped off, they are layout lines.





 
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