GS400e Cafe Racer

[Henrico123]

I recently bought an abandoned Cafe Racer project and decided to get it sorted out. It was intended to be a full nut and bolt build, It might still become one, but for now the aim is to get her running and looking a bit better so I can commute to work with the bike. Work done to date:

- Motor has been sent in to be re-built
- Frame has been cut to fix the horrendous job the original builder did
- Frame has been resprayed - will be done again as I have decided to alter the frame further to create a box where the wiring can be hidden
- I have ordered some goodies to fit to the bike (Mirrors, exhaust, lights, acewell dash etc.)
- I am busy fabricating a steel base for the seat and tail piece

[SK Racing]

Looks great. Keep us informed as you go along. I wish you success!! 

[Henrico123]

Some Photos of work done to date

[Henrico123]

Yes I know the seat is ziptied on, it was the only way to hold it in place. The seat cover needs to be altered to conform to the tank

[Henrico123]

The paint job on the tank and tailpiece is not the best I have seen, but I am fortunate to have a spray booth in my workshop, so I will sort that out going forward. Next step is to fabricate a new battery box and move all the wiring into the space beneath the seat. Hopefully, I will have the motor back next week as well.

[Henrico123]

The original backside on the frame was a bit funky.....

[Henrico123]

Got some more work done on Ugly Suzy this week. Still waiting for the motor to get done, hopefully, I will have it next week.

I closed off the frame loop at the back so I can hide the brake light wiring etc, fabricated a new battery box to hide the battery until I can afford to do a Lithium battery and fabricated a panel to close off the frame above the back wheel (also to help hide wiring)

[Henrico123]

Some more Photos

[Henrico123]

Last of the progress pics. I really need to get a tig welder to neaten my welds. The new steel parts will get epoxy coated after Christmas

[SK Racing]

Looking great. Well done so far. 

I'm dordling with my bike, though. The seat pan is taking up too much time. Still busy refining the mold.

[Henrico123]

My Seat is also still attached with zipties, I still need to figure out how to attach it to the bike, I have run out of ideas....

[Henrico123]

So I have had a chance to play with the bike again today. Bought a used Airage pipe of a guy on FB for very cheap. I know it is not really Cafe racer style, however, I like the sound of these pipes and the shape. I still need to figure out the final placement of the pipe once the motor is back in the bike, but have mocked up a hanger in the meantime. The pipe extends a bit far to the back of the bike, I will need to shorten the Stainless slip-on part of the pipe a bit to move it in and create a bit more wiggle room at the back brake.

[Henrico123]

Mocked-up hanger. This was done out of 2mm steel, once I have finalized the exhaust position I will make one from 3mm plate.

[Jim Knopf]

Servus,

Nice, but the Exhaust is toooooo long!

[Henrico123]

The more I look, the longer it gets!  But in all seriousness, yes, it is too long. Hopefully, I will have the motor back on the 5th of January then I can get a better idea of what will sit where. Also, I realized this morning that the hanger might look better fitted the other way around.

[Henrico123]

Due to Family visits over the holidays and work commitments, I have not gotten much done to Ugly Suzy. I am still waiting for the motor, getting a bit peeved with the rebuilders as they keep making promises that they do not keep, but hopefully, I will have it in the next week or so. In the meantime, I have redone the exhaust hanger and swapped it around so the pointy end connects to the exhaust, looks way better now. Still need to sort out the exhaust placement once I have the motor.

Will probably be re-painting the bike as well in the coming month, our spray booth is getting installed at the moment, cant wait to use it. I just need to decide on a paint scheme, but I am leaning towards the Gulf racing colours, but instead of doing a flat blue, doing a metallic blue.

I am thinking of doing a GSX400R frontend, there is one for sale locally for a good price. Has anyone seen such a conversion or know of someone that has done the GSX400 frontend conversion? I know some guys do the GSX750

[Henrico123]

Quick Update, I have decided to purchase the GSX400r frontend. I Will be picking it up on Thursday, it seems that the bearing sizes are the same, so hopefully it will be an easy fit, but I will do a write-up for anyone else considering the same swap once I have it.

[Henrico123]

Thursday has finally come. now O just need to get this thing fitted

[Henrico123]

I managed to get the Front end test fitted. I will need to make a spacer for the stem, as it is slightly longer, but bearings are the same, so it fits for all intents and purpose. I will do a full write-up on the front end fitment once I reassemble it with the correct spacers.

[moe_tunes]

How did the front end work out ?
Hope you didn't hit any major hurdles, the bike was looking better with each new post.

Cheers