500 K cafe racer conversion - build thread

[Ewan 500 K1]

Anyone ever tried these white wall topper things ?
http://www.ebay.co.uk/itm/160781407385?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

[Ewan 500 K1]

Sooner walk to London with a nail in my shoe that use those. URGH!!!!!!

.. think I was havin a momentary bout of madness

[Ewan 500 K1]

Quite a bit of choice for proper whitewall tyres for 19" front ... but only thing I can find for 18" back are Cockers at (wait for it ) .... £250 to £300. No way ! I might be a poser , but thats a few ££ too far . List of all front and rear whitewalls I can find in the UK attached as a word doc.

[Ewan 500 K1]

NHK ODM500 steering damper (as originally fitted to the Kawa Z1) in place. Much more pleased with this one, it sits much better than the GSXR one. At full right hand lock it just misses hitting the engine. Next up, a wee bit of welding on the frame and then off to the powder coater.

[Ewan 500 K1]

Had to extend the steering stop by 10mm either side to stop the clubman bars banging off the tank.

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Also, one of the rear peg mounts was corroded through and needed welding .

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Finally .... tarozzi rear sets have arrived These will be mounted on the rear passenger footpegs instead of using the tarozzi mounting bracket

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...... so nearly there as ever. Just need to get powder coated and the front muguard rechromed. Bring it on Santa.

These new phot options are great Steve 

[Green1]

Ewan did you disside on a frame finish yet

Mick

[Ewan 500 K1]

dissided to go borin black Mick 

[Ewan 500 K1]

Drilled and tapped both caliper arms today to add grease nipples. The nipples extend through the caliper arm body by about a millimetre so will need a wee washer added so that they dont rub on the pivot pin.

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Also helicoiled the caliper arm mounting bolt holes on one of the forktubes ... near disaster with one hole. The helicoil didnt see to go in right and the bolt was stiff to turn .... = sheared bolt. Managed to drill it and the helicoil out cleanly , retapped and rehelicoiled (phew)

Santa bought me an hour in a gyrocopter from http://www.chrisjonesgyroplanes.com/ instead of gettin me a powdercoating or chroming voucher. I cant complain tooooooooooooo much but if he thinks I'm giving him a hand in a reindeer free present run round the chimneys next year he's got another thing comin. Powdercoatin on hold till a few bills are paid

[Ewan 500 K1]

Yeah I have to add a washer my my grease nipples as well Ewan, it would help to flatten down the area where the nipple goes as it helps seal it a little.

     yeah , forgot about that bit oddjob. I'll get onto it

[Ewan 500 K1]

Yeah I have to add a washer my my grease nipples as well Ewan, it would help to flatten down the area where the nipple goes as it helps seal it a little.

     yeah , forgot about that bit oddjob. I'll get onto it

Rear of both caliper arms flattened off where grease nipples added (thanks for reminder oddjob). Modified washers also added under the grease nipples to prevent then from extending through the caliper arm body and and rubbing off the caliper arm pins

[Ewan 500 K1]

no, not yet applied the grease gun yet OJ, as ever with this reconstruction its all theory till I sort out the powdercoatin an reassemble  the meccano. Got some 90 degree nipples , but they were too big an ugly to the eye 

[Ewan 500 K1]

Dropped the frame, swingarm, botton yoke, rear brake stay, rear brake rod and engine mounts off at WTA Coatings, just outside annan, today   

http://www.wtacoatings.co.uk/

[Ewan 500 K1]

Having failed to find any UK / european suppliers of plugs to blank off the tacho drive hole in the rocker cover, I ordered a couple from america, both meant to be for 750's.

First one, $16 inc P&P from http://www.workingclasschoppers.com . This one is a bit on the loose side and doesnt have a groove for an o-ring. I've stuck on ebay at http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=181299549879

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Next one from member 754 on the US site , this is a much snugger fit and has an o-ring groove. $20 delivered. I think he still has more available.

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[kendo57]

You could just remove the drive and fit a small flat plate over the hole  using the single
 bolt to hold it in place. Mine was like that when I bought it and works fine.

[Ewan 500 K1]

You could just remove the drive and fit a small flat plate over the hole  using the single
 bolt to hold it in place. Mine was like that when I bought it and works fine.

Never thought of that Kendo... probs looks tidier too