Author Topic: 350 cafe starting to take shape (Read 5862 times)

Green550F · « **on:** July 13, 2006, 03:16:02 PM »

Started out as a blue 70 scrambler. It was FREE, froze, and generally F'd up. I hadn't planned on starting another project, but I'd wanted to do one for a long time and the price was right. The aim is to make it work well as possible without spending much. So far I've spent less than $100 on it.

For rearsets, I'm planning on buying a set for a 2002 Buel M2 Cyclone. It looks like they'll bolt right on with little or no modification! And they're only $130 from the Harley shop!

I'm concentrating on the seat right now. I created the shape using expanding foam, added layer by layer, and cut to shape. Fiberglass resin eats this type of foam so I'm setting up the shape and smoothing with bondo. Then I'll put a layer of fiberglass over the whole thing. I think I can use some carpet pad layers to form the seat. Not sure if I should cover with leather or plasti-hide. There are shops for both in town. Amazing considering this is a town of 5300!

cbjunkie · « **Reply #1 on:** July 13, 2006, 04:16:06 PM »

that's going to be a sweet little bike - i love the 350...

why go to the trouble to bondo the seat??? just put down some Saran Wrap and lay the fiberglass on that...

Green550F · « **Reply #2 on:** July 14, 2006, 05:24:58 AM »

I figure it gives me a chance to really fine tune the contour of the seat so the glass will go down with as little work as possible. I'd prefer to have the rough work hidden before trying to make it pretty. It's hard to guage the initial foam and the bondo work really makes the shape flaws stand out.

cbjunkie · « **Reply #3 on:** July 14, 2006, 06:24:36 AM »

so you must be really good with fiberglass?

Green550F · « **Reply #4 on:** July 14, 2006, 12:28:36 PM »

been along time dince I've done much and never more than recontructive surgury. What I have learned is that prep is everything if the finished result is important. such as paint, any mistakes will be magnafied in the final surface!

I'll post more detailed pics at the completion of each phase.

cbjunkie · « **Reply #5 on:** July 14, 2006, 12:35:51 PM »

thanks! i am going to be doing this as well - maybe once it gets cooler again and would appreciate any good hints and tips...

3 sticks · « **Reply #6 on:** July 14, 2006, 02:05:57 PM »

Geez I am pretty jealous right now...

Thats is an amazingly sweet bike! Just what I would like; a 2 cylander with dual drum brakes to cafe. I think it already looks amazing. Keep up the good work and i cant wait to see more!

I guess I really should post about my cafe project..

cheers;
will

Green550F · « **Reply #7 on:** July 15, 2006, 09:56:55 PM »

Ordered the rearsets today! I'll be using foot pegs from a 02 Buel Cyclone. New set with all hardware and a brake pedal cost only $120! aftermarket CBR sets run around $300 and they aren't rubber either! I wouldn't have guessed the prefered set would be the cheaper! Not sure if the mounting bolt is the same size as the old mount, but that is an easy thing to correct.

I'm looking into pod filters and clubman bars next. I could use the bars that are on it, but I think a new set would be worth it.

3 sticks · « **Reply #8 on:** July 16, 2006, 01:59:53 AM »

Or if you really wanted to get fancy, Clip-ons.

Jay B · « **Reply #9 on:** July 16, 2006, 10:25:38 AM »

I like it a lot. I'm on the hunt for a dohc 450 to do next winter.

malcolmgb · « **Reply #10 on:** July 16, 2006, 03:14:09 PM »

Quote from: 3 sticks on July 16, 2006, 01:59:53 AM

Or if you really wanted to get fancy, Clip-ons.

that was my thought too, clip ons look much tidier than Clubman bars along with chrome headlamp brackets

angeldeville · « **Reply #11 on:** July 16, 2006, 08:37:55 PM »

looking good! mine is in process too and should be complete in the next 4-6 weeks.

ProTeal55 · « **Reply #12 on:** July 28, 2006, 12:00:18 PM »

Bike looks great....

I vote for clip-on's as well...

Green550F · « **Reply #13 on:** July 30, 2006, 04:19:38 PM »

well, clip ons would be clean... but I'm settling on clubmans for now. If I change the forks down the road, it'll be clip-ons.

Mean while, I got most of the rearset parts in. Enough to begin working out the mount details and brake/shifter changes.

bill440cars · « **Reply #14 on:** July 30, 2006, 06:09:03 PM »

That 350 is going to be one tough bike. The buel rearsets sound interesting, especially with the price and all. Sure would like to see some pictures and more detail on those. Seat sounds interesting also. Greg, over at ohiocaferacers.com, is big on the 350 and I'm surprised that he hasn't dropped in on this. He must be pretty busy. Keep up the good work Green. Later on, Bill

Green550F · « **Reply #15 on:** August 01, 2006, 06:27:11 PM »

got the clubmans on with the origional grips and replacement levers.
The pegs are pretty clean, but here's the catch: The brake interferes with the exaust!
I'm going to have to add a rod pull point at 90 deegrees to the factory angle. Shouldn't be too difficult.
I think I can reuse the mufflers by tipping and rotating them in. It'll require custom head pipes that will tuck under the frame. To avoid the expense of chrome custom pipes, I think I'll flat black and wrap them. Should look wicked!

Green550F · « **Reply #16 on:** August 01, 2006, 06:29:30 PM »

Pics of the left peg.
I think I could mount another brake lever upside down for a shifter?

Green550F · « **Reply #17 on:** August 01, 2006, 06:32:48 PM »

pics of the right peg and brake pedal. needs some work to pull the rod correctly. To be expected when it was designed to push hydrolics not pull a mechanical rod!

And that pesky exhaust!

ProTeal55 · « **Reply #18 on:** August 03, 2006, 11:47:04 AM »

Is that thing gonna drag on a hard right turn ?

Green550F · « **Reply #19 on:** August 03, 2006, 01:42:19 PM »

shouldn't! it's actually as high as the origional front peg, which was a bolt-on assembly under the frame and exhaust.

Green550F · « **Reply #20 on:** August 08, 2006, 05:43:00 AM »

Had to mod the brake pedal a lot more than I expected. First the origional config pushed a rod up, so I cut that off and moved it 90 degrees so it would rotate forward. I wasn't sure of the strength so I added a gusset.(see first pic) I used some aluminium brazing rod instead of welding in the hope to keep from destroying the pedal. Guess we'll see how that holds up!

Other issues I failed to think of were the need of a return spring and a return stop. Both of which were hidden on the factory setup. I used a drilled out chain link for the spring mount on the frame and drilled a hole for a 1/4" bolt to be the return stop. I cut off the bolt head to dress it up a bit.

cbjunkie · « **Reply #21 on:** August 08, 2006, 06:26:57 AM »

once you get this down pat will you build me a set for the K1?

KCs76Cafe · « **Reply #22 on:** August 08, 2006, 04:34:48 PM »

Looking good.

I wish I could have found an older 450 than my 82 CM 450....but for $100......I couldnt turn it down.

bill440cars · « **Reply #23 on:** August 08, 2006, 07:51:27 PM »

Quote from: KCs76Cafe on August 08, 2006, 04:34:48 PM

Looking good.

I wish I could have found an older 450 than my 82 CM 450....but for $100......I couldnt turn it down.

KC, that's the way I ended up with an 80' Cb750K, instead of an older SOHC 750. The price was right. What else can I say? Better to have them a little newer than not at all, eh?

Later on, Bill

Green550F · « **Reply #24 on:** August 20, 2006, 06:14:24 PM »

Finally got new cables from my ebay bid. First it took 3 weeks to get them and now that they are on the bike, they are a bit long. I supose the clubmans don't help that. They will work but it leaves a fugly loop of cable above the guages! Has anyone had expeience with shortening cables?

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Author Topic: 350 cafe starting to take shape (Read 5862 times)

3 sticks

3 sticks