RETURN FROM HIATUS

It's sad to think the last blog update was back on the 30/03/2016 - over 18 months ago and in that time, no progress has been made on the build.

The time hasn't been wasted; I've been keeping busy with a new job, renovating a new home (including building a work shed) and getting engaged.

After much deliberation, I have decided the bite the bullet and engage the help of a local bike shop to help manage the last of the works. After inspecting some of their recent custom work, I've decided to go work with David who owns The Cafe Racer Shop in Cleveland.

Dave was really open to all the ideas I had and how I had imagined the final product looking. After a bit of back and forward, we agreed on a price and put down the deposit.

Below is a couple of photos of his shop as well as a copy of the document which I provided listing the work to be completed and some guidance of design and colour.

This week, Dave will be stripping down the bike right down the the frame. I'll then be picking this up to finish off the welds, fill in the holes, cut off any unnecessary lugs and tidy up existing welds.

In the meantime, Dave will be sending off the tank and seat cowl for painting.

The plan is to have the bike complete and on the road before Christmas - watch this space!

XR600 Café Racer Build

General Works

• Scuffs on swing-arm to be bogged/repaired so that the paint finish will be smooth
• Tidy up welds and grind back/cut off/fill in all unnecessary lugs and connection points on frame e.g. old foot peg mounts
• Re-build broken part of case so that the chain guide can be fitted to front sprocket
• Connect rear set to gear shifter. New rod and connector to gear shaft from rearsets
• Option: Rear set brackets may potentially need a new design/set-up. Please discuss any changes/options first.
• Install carby – two miss-threaded screws will need re-tapping (believe these are imperial size). Final tune needed – carby jets may need changing to provide smooth running.
• Replace cracked hose to fuel tap
• All electrical wiring. Existing wire loom should make it a lot easier. All wiring to be hidden out of sight.
• New black leavers (clutch and front break). Also replace miss-matching bolts in assembly.
• Shorten speedo cable so that it is a nice tight finish
• Fix tank cap – should have some (if not all) spare parts already
• Fuel tank may need internal treatment for rust
• Grind off old front guard mounts
• Enlarge steering bump-stops so handle bards don’t fit tank
• Install and connect decompression leaver – some parts should already be available
• Wrap exhaust – wrap already provided
• Front shocks need air/oil to get them working smoothly
• Install spring for break cylinder control
• Roadworthy ready for registration
• Rear brake guard to be installed – part supplied
• Option: Replace steering column lock so it can be locked and secured. Let’s discuss if an aftermarket wheel lock will suffice 

Paint

• Engine – two options – let’s discuss final option prior to proceeding

1. Polish/blast engine so that it is all a nice silver colour
2. Paint engine black and polish some accents e.g. engine fins, engine tappet caps etc

• Paint tank and seat cowel. Current colour scheme for tank is a metallic dark green, silver and black similar to existing tank design. Cowel to be metallic green with silver strip and vintage "XR600” decal on rear left hand side only in black.

XR600 text to look like:

• Original “HONDA” emblem to be refurbished and to go back on tank. Please consult on final emblem colours before proceeding.
• Black paint to all frame, swing arm, front forks, triple clamp, fork brace, front guard and all parts including suspension linkages except where otherwise noted.
• Would like some silver accents to tie in with fork tubes e.g. front sprocket cover, rear break cover, chain guide, rear break piston