Mak's step-by-step guide to building an un-original, but still fun, cafe bike

trying to figure out rearsets...planning on using these R6R pieces. They feel good and seem like they'll fit the bill just fine but man do they look "wide". It's like little wings stilling out from the back.

The heel guards will be removed.

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Bit miffed...I've been held up really getting the headers and done because I was waiting for mufflers and I needed to get those positioned before I could really get the pipes in place. And I was held up on pegs because I'm going to have to make them around the exhaust...and the pegs and tray are all I got left to set in place before I can do finish welding, drop the engine, and paint the frame. I had to wait three weeks for the mufflers. I really wanted this left exist high mount dual can setup...I had something real similar with my first CX and I loved it.

But after FINALLY getting the cans in and building the bracket to hold them so I could line up the plumbing...I'm not sure I like it as much as I thought I would.

I'll probably mount very similarly to how they're mounted stock :/...which isn't bad, just isn't as interesting as I wanted it to be.

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Dude I think that set up looks great, just a bit too far set back. Move them forward by about a foot and drop them by 6” and they’d look the business.



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I say 2 into 1 with the muffler where the bottom pipe is in the photo.
 
It's probably going to end up just like that with a can on both sides.

man I wish I could afford $2~3k for laced wheels.

Wheels are my current plight. After a bunch of measuring I sorted out that the WIDEST I can go on the back is a 160mm tire on a 17x4.5 wheel. My plan was to go with a 17x5.5 and a 180 because I really like the feel of a 120/180 combination, but doing that will require a custom drive shaft and I will be very tight on room. Can be done, don't know if it's worth the expense. So I went with a 4.5" wheel...I use to race on a 120/160 combo and it felt good enough so why not.

I ordered up an FZ6 rear wheel since I couldn't realistically make my YZF-R6 wheel work. That way the spokes will match and since it's a smaller rim surely it'll be a small hub and wheel and be a little easier to adapt...

NOPE

The FZ6 hub is significantly larger than the R6 hub. It's 19.5cm wide vs the R6's 17cm the OD on the drive side is way bigger and the center bore is also bigger than the R6. The only thing that's not bigger than the R6 is the cush cavity...it's shallower and the hub is hollow so I can't even mill the thing down. Had this rim been on the R6 hub it would have worked passably.

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For kicks, though...even though I don't like the idea because the wheels are a little on the heavy side...I went out and grabbed my GT650R rear wheel since it's 17x4.5...just to see. The hub is tiny. I would not have any trouble getting it spaced. I may go that route...run the GTR wheel backward, have the drive side milled and maybe have a flange made and welded to it to mount the spline ring on.

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Doesn't look that bad with the R6 front...

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makenzie71 said:
man I wish I could afford $2~3k for laced wheels.

Wheels are my current plight. After a bunch of measuring I sorted out that the WIDEST I can go on the back is a 160mm tire on a 17x4.5 wheel. My plan was to go with a 17x5.5 and a 180 because I really like the feel of a 120/180 combination, but doing that will require a custom drive shaft and I will be very tight on room. Can be done, don't know if it's worth the expense. So I went with a 4.5" wheel...I use to race on a 120/160 combo and it felt good enough so why not.
Click to expand...
You can do laced wheel diy style, shouldn't cost a heap if you can do fab work yourself
http://motosynthesis.blogspot.com/p/products.html?m=1
 
He no longer seems to sell the rings, though...which is a shame because he had the best price. I can get the rings done locally if I can get the dimensions down right, and wheels are not too terrible to source. The problem is getting a hub that'll work with my R6 front. The only hub I could find that was a drop in for the R6 forks was...expensive. The whole setup was something like $2100 with rings from some dude in England, a cheap set of aluminum wheels, and a hub that'd mate up to my rotors and forks that cost like $1000 by itself.

I'm going to stick with the GTR rear wheel. It's cheap and pretty straight forward. I will have to find a machinist that can do a little work for me but it's not terrible.
 
I spent last evening screwing around with the GTR wheel. https://www.facebook.com/duasrodascustoms/photos/a.1724304337848086/2260637270881454/?type=3]I've seen another outfit use them.[/url] I was going to run the wheel backward and drive from the cush side because I wanted a flat surface to attach the spline ring to. But after all my exploratory grinding I'm still about 8~10mm too far. Material there is only about 4mm thick and I think it's critical to the structural support...I don't want to shave it off. That shop I linked to above went from the brake side but going from this side still requires cutting DEEP into the webbing that supports the wheel to the bearing tube. We're talking flush with the spokes and then another 8mm down. I could do it, but I don't know how much trust I would be able to put in the wheel.

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I'm giving up on the rear wheel for now. I'll find a tire that compliments the Sportmax II going on the front that'll fit the 16" rear properly and call it quits...for now. With the swingarm notched already I can probably go ahead and swing for a 150 or 160 but don't know if I will, probably won't fit the wheel properly anyway.

The rear wheel is a thing I want pretty badly but it's not a hill I'm prepared to die on and it's holding up other progress.

At this point I'll probably buy a GL1000 laced rear wheel and re-lace it to a 4.5" rim, and then start looking for a dual rotor hub I can make work with the R6 forks...but will worry about finishing the bike otherwise before I get too deep in that.
 
I got the stuff, had a plan, it can be undone if it doesn't pan out, so even though I was initially skeptical I decided to go ahead and plumb it out....and it's growing on me. It's looking more like what I had in my head and I think I'm going to happy with the end result.

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Okay I REALLY want that high mount left exit exhaust...BUT...I don't have quite enough tubing, it's going to require a LOT of fiddling around to get the tubing tucked away just right, and I'm going to spend a lot of time and effort on it not progressing with the project...not to mention not progressing on all my other stuff I need to be doing. Just like the rear wheel, it's a thing I want but it's not a hill I'm prepared to die on.

So I'm taking the easy way out. For now. I'm going to get more tubing later this year and revisit the high mount next winter.

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That looks by no means awful at all. In fact I think it looks really clean. Enough clearance for your feet/pegs? Sure you've got that sussed anyway. I like the double high pipe set up too, it has a kind of bōsōzoku vibe.
 
Couple of thoughts:

Pipes look like they are right where your feet need to be. I'd be tempted to try both mufflers under the motor with out turned outlets. Like a T120TT Triumph from way back when. That would give a short compact butch look and draw attention to the whole powerplant.

Or extend the header and let them tilt up right behind the footpegs. Would look a little like an 851 Duc exhaust, but could work. and would be relatively easy.

With the over/under shotgun setup, I'd pull them close together and see if that would work. Would look a little like an XR750 HD but on the wrong side of the bike. The combined pipe package might be overwhelming compared to the small seat and large space between wheel and seat. It depends on the look you are going for and how the different design elements work together.

I agree that the footpegs sure are wide on those brackets. Maybe look at shorter alloy brackets mounted to steel plates welded to the inside of the frame so that the mounting brackets are more or less flush with the frame outer face. Or fabricate a frame "extension" in steel to replace the brackets and mount the pegs directly to the frame extensions.
 
I looked at both pipes underneath but there's not enough room...I need a little ground clearance. There's a large cavity behind and under where a muffler could be and some of done that, but I like the look of the pipes. It's temporary just so I can move on with the project. I want to build the exhaust I WANT after the rest is done. I thought about pushing the pipes back but no convenient place the hang them...and not exactly what I wanted.

The pipes are about 1.5" under my feet so I don't think heat or interference will be an issue.

The rearsets wont be an issue until I get a disk on the back anyway...at that point I'm thinking just like you say, a bracket inside the frame to move the pegs in a bit. Right now it'll just be straight pegs bolted about an inch higher than stock.
 
I like that headlamp bracket idea. I'll have to copy that for the wounded Duc. I already have that same headlamp and speedo....
 
Yeah I like that bracket too. Looks solid and built to last. Cool build man. And I'm really liking that exhaust set up, looks brutal.
 
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