Topic: CB750 K7 Cafe Racer Build

[Super Roo]

Got the oil tank back from the welder.
I'm pretty impressed with the design and workmanship.
Now its off to the polishers along with the rocket cover.
Just waiting on the Rickman alloy tank I have ordered before I can finish the design of the rear seat and begin fibre glassing.
The weapon is starting to take shape.
Also attached the clip-ons and had a look at how the carbon fibre from mud guard looks!
Mean!!

[Super Roo]

Bought a Rickman alloy tank from India of e bay.
Rocks up two weeks late, with a dent in the back of the tank.
Tested the tank on the bike and the length is 3 inches short and 1 inch short on the width.
Lucky I was able to dispute it and got money back.
Vendor didn't even want the tank back, not that's its any good for me!

[Super Roo]

Test of how the front head light will look.
The band clamp holding the light into the metal shell is at the top and I'm concerned water will get into the light body.
To move it to the bottom I will need to cut a notch into the light casing to allow room for the clamp tightening mechanism.
 

[Super Roo]

Finally got all of the engine parts machined.
* crank micro polished and balanced
* head ported
* new sleaves installed and honed to 915cc

Have started painting the engine parts.
Just have to get colour on the top and top and bottom cases and its time to bake.
Have to get moving on this beast as its almost spring and summer will be just around the corner!   

[MessnerMoto]

That Ducati front looks excellent. I like to see that someone is trying something different then GSXR or R1 forks conv...

[Super Roo]

Ducati forks are defiantly a lot beefier than Japanese.
Just praying they are long enough.
I am a little worried about the exhaust clearance.
Should have probably got a side winder exhaust to be safe but I already purchased a 4-2-1 race exhaust.
 

[Super Roo]

After the issues with the crap India alloy tank have gone done the path of making my own fibre glass tank.
Starting with making the seat cowl and pan to get the skills up.
Made mould with refrigerator foam. Have finished sculpting now, just a little more detail required around the tank join.
I'm going to make the tank in two parts, a bottom and top.
After which I can mount all of my fittings on the inside and then join the two halves together.
I have a 1" joint around the two halves which is about 5mm recessed, so that a strip can be used to glass the two sections together and the join location will not be visible on the final tank. 
I saw on-line that you coat the mould in duct tape. I used a plastic tape called 'duct tape' although this didn't agree with the resin and warps a bit. I recommend a layer of fibre reinforced duct tape with a cover of painters tape.
Have finished the seat pan. The crap duct tap has left deep ridges that I think I might sand a little. The seat cowl I used the paint tape and the result is much better.
Just have to get some chemical resistant resin for the tank and some microspheres.

[slikwilli420]

Besides the dent is there anything else actually wrong with the tank?

[calj737]

And, be advised! Ethanol fuels will eat your fiberglass tank so a Caswell liner is required.

[SOHC4 Cafe Racer Fan]

And, be advised! Ethanol fuels will eat your fiberglass tank so a Caswell liner is required.

Ballsy move making your own fiberglass tank. Do not skimp on the fiberglass and as Cal recommended, use a Caswell liner.

[Super Roo]

Bit of hard work, but finished the tank.
Made it in two parts.
Used wood jig to hold for joining.
Turned out reasonable.

[Super Roo]

Worked out how to connect EFI throttle bodies to the engine.
First I ported the original rubber mount to suit the throttle bodies.
I ordered 2 90 deg bend silicon hoses that the rubber boots would fit inside and was the right ID for the throttle bodies.
I cut the hose to fit over the rubber boot and throttle bodies and used fuel resistant gasket to connect the two together.
Works a treat.

[JoeCooley]

Nice work!

[Super Roo]

Painted the seat and tank.
Gloss black!
Tossing up if I want to put a gray pin stripe.
Painted myself as I was quoted $800 for paint which seemed steep.
Did tank many hours to smooth the fibre glass.
Dropped the seat pan off to get the seat cushion fabricated.
Should be ready in two weeks.

[slikwilli420]

Want to sell the Indian Rickman tank? Im interested!!

[SOHC4 Cafe Racer Fan]

Worked out how to connect EFI throttle bodies to the engine.
First I ported the original rubber mount to suit the throttle bodies.
I ordered 2 90 deg bend silicon hoses that the rubber boots would fit inside and was the right ID for the throttle bodies.
I cut the hose to fit over the rubber boot and throttle bodies and used fuel resistant gasket to connect the two together.
Works a treat.

Hey another EFI bike! What throttle bodies are you using and what control system?

[Rnobx67]

Your work is amazing, the tank, woah !!!

[SOHC4 Cafe Racer Fan]

Worked out how to connect EFI throttle bodies to the engine.
First I ported the original rubber mount to suit the throttle bodies.
I ordered 2 90 deg bend silicon hoses that the rubber boots would fit inside and was the right ID for the throttle bodies.
I cut the hose to fit over the rubber boot and throttle bodies and used fuel resistant gasket to connect the two together.
Works a treat.

Hey another EFI bike! What throttle bodies are you using and what control system?

And which fuel pump?

Are you transplanting the fuel pump, throttle bodies, etc. from one bike platform or piecing it together.  I didn't see a cut-out for the fuel pump on your fiberglass tank.  Where are you installing it?

[Super Roo]

The throttle bodies are gsxr 750 2008.
It's a complex system with many redundant systems that need to be removed.
I also had to get a gsxr wire harness to get all the wire clips.
The injector clips are denzo.
There are twin injections for each system, so 8 in total.
But they fire as one system, so basically one inject but set as two each side of the butterfly valve.
I have a Bosch fuel pump and an external fuel pressure regulator (aero with pressure gauge) returning fuel to the tank to keep it cool.
Fuel returns to the top of tank.
The controller is a micro squirt.
The fuel pump is way big but it doesn't need to be mounted inside the tank.
Got black anodised fittings and black nylon braided hose for the oil and fuel.
Not mounting the oxygen sensor in the exhaust as it's optional.

[Super Roo]

Got the seat back from upholstery.
Does the job.
Memory foam and gel, should be cumfy as!

[SOHC4 Cafe Racer Fan]

The throttle bodies are gsxr 750 2008.
It's a complex system with many redundant systems that need to be removed.
I also had to get a gsxr wire harness to get all the wire clips.
The injector clips are denzo.
There are twin injections for each system, so 8 in total.
But they fire as one system, so basically one inject but set as two each side of the butterfly valve.
I have a Bosch fuel pump and an external fuel pressure regulator (aero with pressure gauge) returning fuel to the tank to keep it cool.
Fuel returns to the top of tank.
The controller is a micro squirt.
The fuel pump is way big but it doesn't need to be mounted inside the tank.
Got black anodised fittings and black nylon braided hose for the oil and fuel.
Not mounting the oxygen sensor in the exhaust as it's optional.

Wow! That's some work. I imagine that you've upgraded your charging system to something like Anders 32 amp system to feed the extra electrical demands.

[SKTP]

SKILLZ! Looking amazing

[Super Roo]

I have the cycle x external charging system.
Makes the bike kick only, which will be interesting.
Considering I've increase note size.
But does reduce a few kilos in weight.

[SOHC4 Cafe Racer Fan]

I have the cycle x external charging system.
Makes the bike kick only, which will be interesting.
Considering I've increase note size.
But does reduce a few kilos in weight.

I just looked up the specs -- 16 amp system for either the internal or external Cycle X system.  Is the extra 3 amps enough to power the EFI/fuel pump?