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Rotary Recycle USA www.Rotaryrecycle.com - Parts, service and technical assistance specializing in the Suzuki Re5 and Hercules W-2000 rotary motorcycle.

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Old 02-14-2011, 12:18 AM   #1
FC Zach
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Default Café Hercules Build

We have finally decided to start on a cafe W2000 and we hope to have it completed for the DGRR.

The first major purchase was the Ducati 360 tank, it actually fits the bike quite well. Notice the tail mock up and the seat pan we had just started on.


After we came to a stopping point on the pan we then started on the tail section. It was a PITA building the "mold" (whatever you call it), it literally took hours to get this thing right and it fought the whole way.


Once we got a good and sturdy platform to form metal against we started torching the alloy and forming a shape. Here's our rough draft for today, hopefully we'll have it trimmed, smoothed, and ready for welding to the pan next week.


Here's a view of the pan showing how snug it is against the frame.
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Last edited by FC Zach; 02-14-2011 at 12:21 AM..
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Old 02-14-2011, 01:46 AM   #2
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My kind of stuff as you know . the pan needs to not fit as well to the frame IF you are going to cover the seat with materal or leather as the fabric will need to tuck under the pan to be glued or rivited .I have some clipon handlebars that Paul Rotorbrain carried off with the three rd 350s I sold him .The bars were to be returned ,see if he still has them and will send them .Are you making rearsets as well .
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Old 02-14-2011, 02:05 AM   #3
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We're not completely wrapping the pan, just going to have a little pad. We have decided to make our own bars now that we have a pair of Baileigh tubing benders to play with . I initially proposed the idea of using clip-ons but the top triple-tree will be weakened severely after the two post are removed since the unit isn't solid. If time permits we will fab up some rear sets, we just need to get the heim joints and geometry right.

I talk to Tigert on occasion since his father lives in the neighborhood. Next time he visits I'll ask him for you.
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Old 02-14-2011, 07:36 AM   #4
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Nice work. I'd expect nothing less from the premier rotary bike shop in the world.
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Old 02-14-2011, 09:05 AM   #5
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Agree with the dancing queen it's gonna be awesome. You and Jess thought up colors yet zach?
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Old 02-14-2011, 09:48 AM   #6
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This is awesome. Keep it up.
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Old 02-14-2011, 09:54 AM   #7
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LOL (dancing Queen!), yeah Adler, pretty much as you see it. The tank is an NOS unit and we thought would be a shame to deface it. The custom tail we'll have to decide when finished, leaning towards polished/brushed alloy. Keep in mind that this is just a mock-up frame and that the actual frame will be painted but again were unsure as to what color we'll be going with. We're retaining the spoked wheels but with SS spokes and there is a possibility of painting/powder-coating the rims. Still brainstorming
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Old 02-14-2011, 10:01 AM   #8
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Old 02-16-2011, 12:40 AM   #9
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Are you going to put a removable plate and pad for you rear to push against? remove the pad and there is storage for gloves paper work small tools spark plugs ,extra oil . What is the exhast system like?
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Old 02-16-2011, 01:03 AM   #10
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David, its funny you mention that. We were actually talkin about doing that Sun. before we left. We're going to box it in to prevent road debris from denting the aluminum and figured while at it, why not install a little trap door?!? As far as the exhaust goes, I think Jess has a pretty good idea of using a tunable muffler design like the SuperTrapp, and angled up high instead of straight back like originally.
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Old 02-17-2011, 04:01 AM   #11
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Good deal. I am painting the BMW K1 now ( about time ) are you painting the frame and other parts after all the work is complete . What colors ? I have some rear sets for the Kawe if you need to see them for ideas let me know . How much stuff needs to be hidden away such as a battery and electrical parts ,2 cycle oil tank , tools , Are you raking the frame alittle for better high speed handleing,lowering the bike to handle better.Making the swingarm parallel to the ground .lighting the wheel hubs ,stronger SS spokes, lighter alum rims sticky dual compound tires . Small front fairing . frame sliders.alum body side covers , ram air air filter How much fun are you allowed to have?
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Old 02-17-2011, 11:23 AM   #12
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LOL, you've been about to paint that BMW for years, it's about time! We're going to paint the frame (probably rattle can and just a basic color like black). As far as hiding stuff goes. . . well, were pretty much deleting things such as the battery, unnecessary wiring, and switches. It'll be kick-start only if we can get a better designed and higher quality kick-starter made then we can delete the starter and block it off. I presume we'll be premixing since oil injected models are extremely rare. As far as frame modifications go, it's all about how much time we have. We were debating doing a leaf spring rear (pretty sweet), but that'll have to wait. So instead were going with a higher quality coil over in the rear (slightly lowered) and retaining the Grimeca forks up front. The only input I have on the wheels is that they will be spoked and with SS. The biggest problem we have is time, we will get done what we can and save the more in depth modification for a later date.
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Old 02-17-2011, 05:34 PM   #13
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David,

You would know what it looked like if you actually came to visit... I know it's one HELL of a long drive... but hey

Best,

Jess
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Old 02-18-2011, 12:11 AM   #14
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I will come there after I get some more of the BMW parts done .Song and I go to Telle to eat some times .I will call first .
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Old 02-18-2011, 01:05 AM   #15
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Hey David, when you drop by and if you remember could you bring the Suspension Techniques papers you reminded me about since I kept forgetting to remind you at the drive-in shows?
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