Topic: CL350 Street Tracker / Cafe build

[grcamna2]

madS,
I know they're out there but I can't remember what a common name would be,a fastener company will know,ask for 6mm x 1.0 I know of a name called Timesert which is an expensive brand that comes w/ the whole kit to fix stripped out holes.

[madScientist]

I did some research and found "E-Z Lok" fasteners that look like they might work. I was going to see about picking some up and seeing how they go.

I have the welds satisfactorily cleaned up. I could probably keep touching them up but I think they are fine. I also cut the center stand mounts off.

Next up is to clean up the side cover mounts.

I did a little clean up on the rims as well. There's some blemishing on them but overall the chrome is in pretty good condition. I figure I'll get new spokes for them and paint up the hubs but the rims are okay.

[madScientist]

Well the original plan of cutting, bending, etc of the electrical box fell through since I realized that the rear down tubes climb at an angle and are not parallel like I foolishly thought. Backup plan :-D

I picked up some 20 gauge steel since I suck terrible at welding 22 gauge with the mig welder and then began cutting. I first cut the back plate trying to match the decreasing width of the tubes. The tube mounting points also posed a problem since they are gusseted in which really jacked with my calculations. After some more grinding and fitting it fit nicely. I have cut 1" strips and started fashioning the sides. I have the sides welded on the box but had to call it a night...plus that sucker is too dang hot for me to be touching.

Please forgive my welds on this one. I had the line speed turned up a little too high at first. It looked and sounded like it was welding fine but when I lifted the helmet the welds looked...well...not to my standards but they'll do. I also welded too much too fast so it warped slightly...rookie mistakes. It's fixable though.





Work is going to be crazy this week but I'll post if I get a chance to work on it some more. I need to recut the bottom piece, weld both the top and bottom in, cut/bend the cover, clean it up, and figure out mounting.

[calj737]

a little paint or powder coat, and that thing will look #$%*in'  Cant wait to see that all mounted up!

[madScientist]

Finally got some garage time today. Degreased and pressure washed the crap out of the engine cases (I'm still soaked). After letting them dry for a couple hours and blowing them off with the air compressor I decided to paint them.

I wiped them down with an acetone soaked rag (i was wearing gloves) to get the last bit of oil residue off. Now I usually use VHT paint but as luck would have it i'm out of primer and aluminum :-/ So I settled for Duplicolor. I think it turned out pretty darn good. I gave it a healthy shot of primer and then about 3 coats of "aluminum". This was the just the lower half of the engine. The jugs and head are going to be satin black. The breather cap and cam cover will also be aluminum. However I haven't even had the jugs bored yet so I'm waiting to paint those. Knowing my luck I'd probably chip them.

I put the cases together with a couple bolts to show off the work so far.





I'm still working on the frame and the electrical box. As I make more progress I'll report back.

I'm intending on dropping the pistons and jugs off at the machine shop next week. I need to take inventory on bolts as all the hardware will be stainless allen bolts. Anyways...i'll report back later.

[grcamna2]

Chase,
Those cases look excellent;did you rebuild the head yet ? I wonder if the PO I got it from ever ported it ?
it sounds like you have a Nice full shop in your garage 

[SOHC4 Cafe Racer Fan]

Very nice prep and paint.

[madScientist]

Thanks fellas!

I haven't rebuilt the head yet. I have to get that fin fixed and get them bead blasted. I was thinking the same thing about the porting. If I get out to the shop today I was going to compare port sizes to the other head just out of curiosity.

Yeah I have a wide range of tools :-D. I dont like renting things as I know I'll end up needing it again later. So when I come across a need i either go out and buy the tool or wait until I can. I want to upgrade the compressor to a Quincy two stage and I could REALLY use a plasma cutter. I can get by without them for now.

[grcamna2]

That Quincy two stage is an excellent quality compressor,along w/ an old Kellog.
If you find either one,even worn out,they're Very rebuildable;just make sure your tank isn't rusted out...

[madScientist]

Back from vacation and got a little garage time in. Got the frame all painted up, installed the "All Balls" steering bearings, and put in the triples. The forks are still awaiting a rebuild. I also put in a purchase of various seals, swingarm bushings, and misc other parts. Should be able to make some good progress this weekend provided everything shows up.

Before I left I dropped the jugs, pistons, and head off at the machine shop for blasting and boring. I expect to hear back from them this week as well. The only thing I dont have to put the engine back together (excluding the head that needs to be rebuilt) is a cam chain roller assembly. I think I'm going to bite the bullet and get one of the bore-tech ones since, it would seem an original is almost the same price. The chain guide is also shot so I'm going to have to source one of those. I would also like to put a manual cam chain tensioner on it if I can find one.

I did start putting the motor back together as well. I got the crank installed in the upper case half and started putting the gears in. However they are fighting me on meshing up and seating. I started getting frustrated so I left it alone.

Here's a shot of the frame with my dog photobombing...

[SOHC4 Cafe Racer Fan]

Great work as always, MadS.

[SOHC4 Cafe Racer Fan]

Do you have any pics of the seat you'll be using. I didn't see one in the thread. Could be glitch with my iPhone but some of the earlier pics are not displaying.

[grcamna2]

That's a nice 'shop dog' 

[madScientist]

Thanks. She's a great pup although she's gettin' old.

I dont have pictures of a seat yet as I haven't made it up. I'm going to be making a seat / cowl out of fiberglass similar to what I have on my F. I really like how it looks. The trick will be getting it to look right with the tank. The tank has a "bobbed" look to it which i dislike. I was going to put a CB tank on it as I think those are more "leaned forward". I will not be modifying my current tank as it's straight and fairly clean.

Similar to this:
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[grcamna2]

I like the CB tank myself

[SOHC4 Cafe Racer Fan]

Thanks. She's a great pup although she's gettin' old.

I dont have pictures of a seat yet as I haven't made it up. I'm going to be making a seat / cowl out of fiberglass similar to what I have on my F. I really like how it looks. The trick will be getting it to look right with the tank. The tank has a "bobbed" look to it which i dislike. I was going to put a CB tank on it as I think those are more "leaned forward". I will not be modifying my current tank as it's straight and fairly clean.

Similar to this:
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I myself am a fan of the 750 SS style tank but that might be a little large for a bike like this. I wasn't sure if you were going to run a classic tracker style seat - flatter and winged outward by comparison.

Looking forward to what comes.

[madScientist]

Sorry i should have clarified...i meant a CB350 tank. I'm not going to try and jam an F tank on it. I still want to run a battery which is why I was going to put a hump in it. I am researching the smallest usable battery.

I hate kick starting...I'm intentionally withholding the electrical box pictures :-D

[madScientist]

After some research I found this guy:

http://shop.antigravitybatteries.com/antigravity-batteries-ag401/

At less than 4" tall and 1.25" deep I can probably stash it in the electrical box.

[SOHC4 Cafe Racer Fan]

After some research I found this guy:

http://shop.antigravitybatteries.com/antigravity-batteries-ag401/

At less than 4" tall and 1.25" deep I can probably stash it in the electrical box.

The four cell is only recommended for street use up to 250cc OR race use up to 600cc, so I think you might be pushing your luck with it for your 350 twin.  The smaller size is easier to hide, but  it might lack enough amps it your engine is cold.  I would recommend going with the 8-cell (http://shop.antigravitybatteries.com/antigravity-batteries-ag801/).

I have heard mixed reviews about Ballistic, nothing but good reviews about Shorai, and nothing bad about Zero Gravity or Alien Motion.  I have Alien Motion batteries in my 750 and 550.

[grcamna2]

That's a nice little battery;I'm sure you'll be going all through your electrical/charging system and 'feeding' that little guy just what it requires.

[madScientist]

i think I could hide that 8 cell fine. I am going to roll through the electrics and fix / replace most of the wires. I'll likely be fashioning up a new harness altogether as mines somewhat roached out. It's getting a recticfier / regulator from oregon electrical. Lighting will be LED.

[SOHC4 Cafe Racer Fan]

i think I could hide that 8 cell fine. I am going to roll through the electrics and fix / replace most of the wires. I'll likely be fashioning up a new harness altogether as mines somewhat roached out. It's getting a recticfier / regulator from oregon electrical. Lighting will be LED.

I think the new harness, reg/rectifier and LED lighting is a good call.  I have been the victim twice now of "roached out" wiring.  You will want to add an electronic LED flasher unit to that list, too.   

If you go with a LED headlight, like the Truck Lite, you will likely need a metal headlight bucket, as the stock will crack under the strain of the metal light housing.  No fun when you are on a ride, and the headlight bucket breaks after hitting a bump in the road.

[grcamna2]

i think I could hide that 8 cell fine. I am going to roll through the electrics and fix / replace most of the wires. I'll likely be fashioning up a new harness altogether as mines somewhat roached out. It's getting a recticfier / regulator from oregon electrical. Lighting will be LED.

I think the new harness, reg/rectifier and LED lighting is a good call.  I have been the victim twice now of "roached out" wiring.  You will want to add an electronic LED flasher unit to that list, too.   

If you go with a LED headlight, like the Truck Lite, you will likely need a metal headlight bucket, as the stock will crack under the strain of the metal light housing.  No fun when you are on a ride, and the headlight bucket breaks after hitting a bump in the road.

What does that LED headlight assm. look like CB750 CRF ?

[seanbarney41]

Sorry i should have clarified...i meant a CB350 tank. I'm not going to try and jam an F tank on it. I still want to run a battery which is why I was going to put a hump in it. I am researching the smallest usable battery.

I hate kick starting...I'm intentionally withholding the electrical box pictures :-D

uh oh...if you have never owned one of these little bikes before, you might want to change your mind.  Even when working perfectly, they tend to not want to spin the starter motor under many circumstances.

[grcamna2]

Sorry i should have clarified...i meant a CB350 tank. I'm not going to try and jam an F tank on it. I still want to run a battery which is why I was going to put a hump in it. I am researching the smallest usable battery.

I hate kick starting...I'm intentionally withholding the electrical box pictures :-D

uh oh...if you have never owned one of these little bikes before, you might want to change your mind.  Even when working perfectly, they tend to not want to spin the starter motor under many circumstances.

The battery has to be 'Hot' 100 % charge and I think(from what I've heard about those Rick's reg./rect. & stator pckges.)it should spin it better than stock.I've never owned or installed a Rick's set-up but I keep all my ground connections & rect. ground + terminals tight & shiny w/ a stock system.