The End...Again.

XS650 Cafe

I decided to call an end to this project because it was dragging on too long and really taking tim away from other projects that I want to concentrate on.
I kept the frame, swingarm and body (tank, fender, seat cowl) pieces and sold most everything else.

Equipment

I have pieces of structural metal (pipe, tubing) that has been laying around my garage for the past few years. I have some ideas for some tools that I want to build that will make use of this metal. So that will be my focus, in addtion to metalshaping, over the course of this year.

I am intending to build these tools:

1. Belt Grinder - I have been wanting one of these tools for a couple of years now, especially after seeing different variertys of grinders based around the Beaumont Tools design. I have bought a non-working treadmill to use the DC motor from it, and have the metal on hand to fabricate most of the grinder. Having a tool like this around will be helpful when I fabricate pieces from flat metal stock that have radiuses/curves to them.  
2. Reciprocating Machine - I don't have that much time to metalshape these days, so I want to increase my productivity in the little time I do have. A reciprocating machine with the correct tooling installed will allow me to create compound shapes quicker. I am going for a small throat design (8") due to space contraints, but that should work well with the size pieces I metalshape. 
3. Metalshaping Stand with Switchable Tooling - I have had a stand I built five years ago from a couple of harrow blades and a section of round tube. It worked, but I haven't been that pleased with it. I want something that will be more odular so that I can switch tools on the post i.e. sandbag, stump, post dollies, tucking forks etc. I will use a 2" hitch receiver mounted vetically as a receptacle for other tools attched to 2" shafts that will slip into the stand.

Hey Bucky

Masekarti

I have been putting in some hours designing the buck from the 3D model I created earlier.

The issue I had before starting the buck design was, how complex/simple do I make it?
Because this is going to be a one-off project..well maybe a a two-off. I initially thought of ways to make the buck as simple as possible. But because I am a novice metalshaper, and I need all the help I can get, I decided for a more complex buck that will give me more surface information.

The next steps are to create the drawings from teh buck model and get 1:1 drawings printed so I can start cutting the buck stations out of plywood/MDF.

Four wheels

Masekarti

One of my long term dreams is to build my own sportscar. The three things that are most needed in a project such as this -- that I don't have currently -- are space, time and money.
So to give me the feel of this type of build without the above requirements, I figured I would scale down the build somewhat. So I'm going to build a approx 1/3 scale minikart. I was thinking intially a pedalcar, but because the body is going to be fairly narrow, an electric minikart is a better option.

The intent is construct the Masekarti similar to a real car build. So it will have a sheetmetal or aluminum body and a simple ladder frame chassis. I will be using 10" diameter spoke wheels on it and it will be powered by an electric sccoter motor (250W-350W) with a couple of 12V battery packs and a speed controller.

I figure the Masekarti should be good for 20-25km/h with 3-5 year old child piloting it.

So what I am going to build? Well, I have an appreciation for vintage/classic sportscars and racing cars from the 1940s/1950s/1960s time periods. So I have decided on building something similar in spirit to the 1949-50 Masertai 4CLT.

With the make/model of car selected, the next task is to make a 3D CAD model of it. The purpose of the model is to build a buck that I will use to help metalshape the  Masekarti body.

I went online to a couple of sites that have freely available blueprints and found the one I needed. So after putting in a number of hours, I came up with this basic model. I still have to design the chassis and other mechanical pieces (steering, front/rear axle mounts etc), but this model will allow me to create the buck and start metalshaping.

Rust Never Sleeps

XS650 Cafe

I have had my gas tank, seat cowl, fender and battery tray in bare metal for some time now, and they were starting to gather surface rust. So I did some preliminary prep work and blasted them with primer.
This is an intermediate step until I get them painted early next year. 

I got a start on welding the exhaust headpipes. I still need to weld on the flanges that attach the headpipe to the engines, and build the mufflers. But that will be done early spring next year.

I removed the engine from the frame and will be ready early spring next year to paint the frame and clean the engine up.

Just Exhausted

XS650 Cafe
I have started to put together the exhaust system. I am using 16g stain steel tube comprising of 90 degree bends and straight tube. The next step after the headpipes have been fabricated is to build the mufflers. I will be fabricating reverse cone muffler from 20g stainless steel.

Other Motorcycles
I was able to pick up for a reasonable price, two more motorcycles that had both been disassenmbled. The motorcycles are a 1972 XS650 and a 1971 CB350. So my plan is to build another Cafe Racer from the XS650, using an aluminum tank, seat and fender set that I have been working on. For the CB350, my initial plan is to build a streettracker with a vintage feel/look to it. 

Still at it

XS650 Cafe

I am trying to finish up leak test/repair on the tank this week, and then I can seal it.

For leak testing I hooked up a bicycle pump to one of the petcocks, and used a spray bottle with soapy water to check the joints. I found a a number of pinhole leaks that I sealed up using lead solder. I decided to use solder instead of welding to minimize the amount of heat being applied to the metal. Welding the pinholes would require to much heat leading to more warpage.

I will be coating the tank with POR-15 sealer, so if I miss a pinhole or two, it will be sealed. I would just prefer to eliminate as many leaks by soldering them first.

I also cut out the padding that will be going on the seat cowl. I stil deciding if I should increas the thickness in some areas.

Starting to mockup the exhaust header pipes. I need to get some stainless filler rod, then I can proceed to welding the tubing.

Back at it

CNC Mill

It was fun while it lasted, but I decidede to sell it to free up the (little) time I have to focus on my metalshaping/motorcycle projects.

XS650 Cafe Racer 

So I am back at the motorcycle project. I have to work furiously now to get what I can done during the summer.

The gas tank now has the fillercap, petcocks and front and rear mounts installed. I designed the front mounts such that they use the stock frame ears. It works well.



I reworked the seat cowl to butt up to the tank. When I get around to upholstering the seat cowl, I can make it flow from the gas tank. 



The front fender is completed, I am now working on the mounting for it. I will be creating a fender mount that is also a fork brace.



Here is a pic of the gas tank and seat cowl set on the frame.



The exhaust system is being worked on also. I am creating it out of 1 5/8" stainless steel  tubing. It will be 2-into-2 system with short (15m") megaphone mufflers.

 

 Miscellaneous Metalshaping

In my last entry I mentioned starting to work on creating a gas tank and seat cowl out of aluminum. Here is the original tank that I am using as a reference.



I have started to shape the tank pieces. Here are a couple of pictures showing the progression from flat sheet to some rough shape.

  

Here are a couple of pictures showing the seat cowl buck and the initial shaping so far.

 

I am also creating in aluminum another gas tank identical to the steel one that was made for the Cafe Racer. Here is the progress on that so far.



To weld these tanks and seat cowls I will be using gas welding, same as I use for welding steel sheetmetal. Gas welding sheet aluminum has it's own challenges, and is more difficult than steel sheetmetal. Why use gas welding for aluminum? Well, aside from it being the only welding equipment I have available, gas welding aluminum allows for a stronger weld. Gas welding can achieve full penetration of the weld joint more effectively than TIG welding.

Here is my first crack at gas welding aluminum. The first picture is the weld bead, the second picture is the weld bead filed down. Both pieces were butt welded.