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Old 04-03-2015, 03:53 PM   #21
DSM
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After many failed start attempts and a handful of actual start ups with loud popping, I have finally figured it out. It turns out that my front and rear ignition coil plugs were swapped! There was a discrepancy between my manual's wire diagram and general consensus online about front vs rear cylinder on the ignition wiring (orange and gray wires). I knew my problem had to be something stupid like this. Well now she runs and sounds great, but there is still some carb tuning to be done. She still pops a bit, but not nearly as frequently or as loud as before. I also think I need to re-adjust the front exhaust valve lash. Downhill from here!

Last edited by DSM; 04-03-2015 at 03:55 PM.
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Old 04-03-2015, 04:16 PM   #22
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awesome.
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Old 08-28-2015, 01:10 PM   #23
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Update!!! please I want this bike so bad
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Old 08-28-2015, 01:23 PM   #24
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Sorry for the lack of posts. I've been really busy lately and unfortunately my bike has taken backseat for a bit.

I need to refine the shape of the tank just a bit more, and then I can start glassing the foam to make the plug. The photos with the light gray tank are the bike as it sits now. The dark gray is some photoshop work to get an idea of how I want to refine the shape of the tank and possibly lower the subframe angle a bit. Thoughts?
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Old 08-28-2015, 02:43 PM   #25
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i think the slight forward angle you have right now is good because it gives it more of a modern look instead of the typical honda cb look of a complete level flat frame. also on the knee indents make sure the angle of the vertical line matches the angle of you shin bone so it makes the bike look more of a custom fit made just for you. so just round and up lift the bit of sub frame that's sticking out and dont forget to fill the gab between the seat and gas tank cause i think it makes a cleaner line if there's no break.... sorry for the rant but i have had my eye on viragos for a really long time and yours looks exactly how i would do it. Keep it up !!
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Old 08-28-2015, 04:46 PM   #26
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This is not helping my urge to want to build a cafe racer my gf officially hates this post and im.officially gonna follow it until you finish.
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Old 08-28-2015, 05:13 PM   #27
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Thanks Jenk's, I think you're right, the dark gray one looks a little too much like the CB, and I really do want the more modern look. I tend to go back and forth in my head about what I want. I will also take a look at the tank knee angle and make sure it's just right. I definitely don't want to do all the fiberglass work and have the tank not quite right. About the gap between the seat and tank: that seat is technically on old one I made for a previous project, but I am liking the way it looks on this bike. All I'd need to do is cut a notch in the seat to match the tank shape and it should sit nice an flush. I haven't addressed the protruding sub-frame yet because I haven't finalized the seat design. If I do end up using this seat (which is very likely) I will bring the end of the subframe up under the fender and fashion a bracket for attaching my tail light.
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Old 08-28-2015, 10:54 PM   #28
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Quote:
Originally Posted by DSM View Post
Thanks Jenk's, I think you're right, the dark gray one looks a little too much like the CB, and I really do want the more modern look. I tend to go back and forth in my head about what I want. I will also take a look at the tank knee angle and make sure it's just right. I definitely don't want to do all the fiberglass work and have the tank not quite right. About the gap between the seat and tank: that seat is technically on old one I made for a previous project, but I am liking the way it looks on this bike. All I'd need to do is cut a notch in the seat to match the tank shape and it should sit nice an flush. I haven't addressed the protruding sub-frame yet because I haven't finalized the seat design. If I do end up using this seat (which is very likely) I will bring the end of the subframe up under the fender and fashion a bracket for attaching my tail light.
Sounds like a plan
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Old 10-05-2015, 02:05 PM   #29
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Status Update: Tank Process + Kickstand Mod

Ok all, sorry for such big gaps between posts.

I have coated the foam tank in epoxy in preparation for fiberglass and bondo application. The goal being to turn the foam into a 'plug' (perfect replica of the final tank shape) which will then be used to make my mold. I will also be working in a way to attach the stock fuel petcocks to my custom tank. Just received my petcock rebuild kits. I was originally planning on using some aftermarket petcocks that were gravity fed only (inturn closing the vaccuum ports on the carb boots); however, that seemed to produce carb overflow problems. I think the flow pressure was too great for the floats to handle. So I will use the stock vaccuum ports and this should create the ideal fuel condition.

I also chopped the kickstand down. The R6 front end I used lowered the bike quite a bit which caused the existing kickstand to be too long (bike stood straight up in danger of tipping). Now after cutting and welding the foot back on, I have a comfortable lean. (sorry for the sideways photo, posting from my phone today)
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Old 10-05-2015, 04:16 PM   #30
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sweet and I like the animated drawing
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Old 10-05-2015, 04:19 PM   #31
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Quote:
Originally Posted by Jenk's View Post
sweet and I like the animated drawing
Thanks. Gotta love Sketchbook mobile. I Don't always have pen and paper on hand, so my phone becomes my sketchbook.
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Old 10-05-2015, 10:22 PM   #32
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I've been wanting to put upside down forks on the Street tracker for a while. Did a lot of research, as I'm sure you have. Just wanted to put this out there...
At least in the case of XS650's, the shorter upside down forks cause enough change in the front end geometry to make the bike, pretty much a handful to ride. The handling is so quick that you have to be extra careful. Tank slappers, wobbles, etc. are a possibility.

Just saying, if you aren't aware of all this, be careful the first time you ride. If you are aware, then I'll shut up, ha.

One more thought. If you PM me dimensions, I may be able to get you a piece of carbon fiber cloth to use as the top layer for your tank, so it looks like a carbon fiber tank.
No I can't get free carbon fiber for everybody, so please don't ask, but I like this build and I'll try this one time.
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Old 10-05-2015, 11:59 PM   #33
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Good to know! Would you recommend a steering damper?
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Old 10-11-2015, 06:12 PM   #34
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Status Update: Speedometer and Tank Progress

Just installed an Acewell Speedometer/tach. I was able to fab up a small bracket to mount the speedo to one of the ignition mounting bolts on the upper tripple. It worked out pretty well. I dig the look. I also love the fact that all the indicator lights are housed in the unit. It's sleek and the included magnetic speed sensor eliminates the headache of figuring out a speedometer cable setup (these forks don't have a way to connect an analog setup).

I started glassing the foam tank. Gonna be a while before it's ready to build by mold. This stuff is pretty labor intensive. But I'll keep chugging away. Oh, and I'm pretty settled on my decision to do a carbon fiber skin on the tank, though I'm not sure whether I wanna go satin finish or gloss. I'm going to do a vintage looking tan leather for the seat. I will probly use a nice looking vinyl for the upholstery.
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Old 11-05-2015, 10:54 PM   #35
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keep It going man !
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Old 11-05-2015, 11:14 PM   #36
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this is awesome. Ive seen a virago cafe build before and they are sweet, Id probably rock one myself
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Old 11-06-2015, 12:19 AM   #37
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Status Update: New Toy

Well... I have been distracted by my new toy. 3D Printer!
I've been calibrating and printing and calibrating some more and printing more! To save money I bought a kit that required complete assembly. It was a lot of work but it was fun and totally worth it. I designed and printed a spanner wrench for one of my first prints. The plastic is surprisingly strong.

So about my bike... I've decided to make a slight detour in favour of time. My car (inherited from my grandmother) is on it's last leg. It wasn't cared for too well before it landed in my hands and so now I need to put the bike on the fast track so that I can have a working ride. What this means is the fiberglass tank is going on hold and the stock tank will be used. It's gonna require a bit of cleanup, but will be a lot quicker and easier. I am not giving up the custom fiberglass tank, just putting it aside for now. The stock tank looks ok. I like my custom tank better, but this will suffice for a while.

As far as time goes, I have a wedding coming up next weekend (14th) , my wedding so I won't be back on the bike project until after the honeymoon. But with the stock tank plans it shouldn't be long till she's on the road!
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Old 11-06-2015, 12:39 AM   #38
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that looks awesome...I know nothing of 3d printers but I want one
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Old 04-25-2016, 12:55 PM   #39
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Progress Update

My project progresses slow and steadyÖ

attachmentphp?attachmentid92209&ampd1461605620

Tank:
attachmentphp?attachmentid92210&ampd1461605620
I recently switched directions on my tank in favor of time. The complete custom fiberglass tank will be put aside as a project that I can work on while the bike is rideable. In the meantime, I have "skinned" the stock tank giving it the appearance I am after. This was accomplished using leftover pieces of pink foam and fiberglass. it looks rough right now, but once sanded and painted, it should look pretty sleek. I have also started modding the seat to better fit the frame.

Foot Controls:
attachmentphp?attachmentid92211&ampd1461605620
I finally worked out both foot controls, now I just need to finish up the custom rear brake arm I made this weekend (trim excess metal and paint). I havenít snapped any photos of the shift linkage and completed left foot peg yet.

Front End:
attachmentphp?attachmentid92213&ampstc1&ampd1461605998

I put new rubber on the front wheel. I finally replaced the old seals and added fresh oil to the forks. That was an adventure to say the least. I ended up fabricating a custom fork spring compressor to do the job. I managed to modify a long one-handed bar clamp while retaining its use as a clamp. I made a damper rod capture tool from a tube and nut. Southland Hardware has come to my aid many times for this build. They have those hard to find metric sizes that home depot doesnít carry.

attachmentphp?attachmentid92205&ampd1461604924

I shortened up the clutch cable. I used a pretty neat technique that I found online.
Cool technique ---->

attachmentphp?attachmentid92199&ampstc1&ampd1461605998
attachmentphp?attachmentid92200&ampstc1&ampd1461605998

I have been brainstorming some headlight mounting ideas. I came across a setup that I like while browsing the web. I think I may try to fabricate something like them. The sketch I have uploaded shows how I might make the fork clamp mount (the steps aren't in order in my drawing). Then I will make the brackets from either fiberglass or aluminum. I would prefer to use carbon fiber, but these will be functional prototypes until I get my hands on some carbon fiber cloth.

Itís probably safe to assume that it will be a while till my next post.
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Old 04-25-2016, 01:34 PM   #40
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looks good!
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