Café Hercules Build

[FC Zach]

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.
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9697&d=1297663930

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.
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9698&d=1297664052

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.
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9699&d=1297664114

Here's a view of the pan showing how snug it is against the frame.
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9700&d=1297664272

[Garfinkles Motor Works]

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 .

[FC Zach]

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 :hurray:. 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.

[My5ABaby]

Nice work. I'd expect nothing less from the premier rotary bike shop in the world. :icon_tup:

[IH8DSM]

Agree with the dancing queen it's gonna be awesome. You and Jess thought up colors yet zach?

[ChaserAero]

This is awesome. Keep it up.

[FC Zach]

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 :confused:

[My5ABaby]

:squint:

[Garfinkles Motor Works]

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?

[FC Zach]

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.

[Garfinkles Motor Works]

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?

[FC Zach]

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.

[RotaryRecycle]

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:nopity:

Best,

Jess

[Garfinkles Motor Works]

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 .

[FC Zach]

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?

[Garfinkles Motor Works]

I have the papers for you .Doyou still have a long oil cooler for my 2st gen with the twin turbo motor ? Your cafe seat need a plate from the pan in front going up to the rear of the gas tank covered with the seat pad to protect your man parts if you slide foward .Many many years ago in a place far far away ,,I degress,, I built a 250 Duke cafe with a silver met frame and dark purple met tank ,seat ,side covers .Looked great and sold fast,went fast as well .Are you painting the tank seat ,sidecovers head light ? If you get all parts to me so there is no rush I might paint it for you if you pick the correct color .No rush but ready for the dgrr in plenty of time ,You get the parts ready for primer ,my inspection .NO RUSH must be ready in one day bull as on OCC .

[FC Zach]

Yeah, I still have the cooler. If I remember I'll bring it to the shop Sun. when I come. Yes the pan will be padded. The tank I not getting painted, "The tank is an NOS unit and we thought would be a shame to deface it." and everything else is somewhat of an afterthought since we're basically still brainstorming and mocking-up everything. Thanks for the offer!

[FC Zach]

Today we did some finishing work on the tail section, almost ready for welding.
Jeff removing unnecessary metal:
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9735&d=1298263883

I played around with this a while, got it fairly straight:
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9736&d=1298263902

The exhaust came in too.
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9737&d=1298263916

[Garfinkles Motor Works]

Do not grind and spray sparks on the new chrome pipe .Sparks will mark chrome and SS as well .You have been watching OCC for to long .

[FC Zach]

OCC, whats that? LOL, I don't watch TV or have cable.

[Garfinkles Motor Works]

No tv or cable well good for you ,more time to work on bikes and your RX .The less tv I watch the better and OCC people are building rolling LAME. Tell Jeff HELLO for me .Is he working on a turbo bike ? I remember him saying something about it .

[FC Zach]

Will do. No, I dont believe he is building a turbo. He currently messing with a Suzuki GS850 Bobber.

[FC Zach]

Here is a Pic.
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9738&d=1298277683

[IH8DSM]

Haha jefferies looks like such a badass wonder if he'll let me ride doubles hahaha

[ChaserAero]

Mannnn...sleeveless and shorts!?!?

Nice build. Good progress and less OCC the better.

[FC Zach]

^ ^ LOL, thanks!

Adler, I dont know where you would sit? ? ?

[IH8DSM]

That's not a no haha

[Garfinkles Motor Works]

If any one wants to build a Kaw four cyl with a turbo I still have a ton of stuff to sell ,truck load . All old school and race parts .Tonight I am going to start making a handle bar mount for the triple tree I made for the mini mini 50 Indian . Getting to use the wire EDM is great.Yes it is the same model as on PAWN STARS .I bought it for Kerry when he was 4 years old in 1974 .I am modifing it to hold a heaver person .Post more pics of the cafe as you get things done .

[My5ABaby]

Adler, I dont know where you would sit? ? ?
On Jeff's lap.. duh... :willy_nilly:

http://images.nymag.com/images/2/daily/2010/04/20100415_tomcruise_190x190.jpg

[almoststockfc]

Fags and yes I never post bring on the hate mAil

[FC Zach]

Welcome to the forum Jeff! :hurray: LOL

[FC Zach]

This weekend we got our new shocks in, pretty well made units.
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9765&d=1298863289
Did a little more work on the tail and made a plate to box in the section.
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9766&d=1298863310
Today we made the side fairings, very proud with how they turned out. They fit very nicely.
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9767&d=1298863325
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9768&d=1298863342
http://www.rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9769&d=1298863355

[Garfinkles Motor Works]

Shocks look really nice .Button head allens on the side covers please .

[FC Zach]

LOL David, we got the hardware. Just mock-up for pics.

[Garfinkles Motor Works]

I made a new triple tree ,crown plate and handlebar mount for the mini mini Indian this week .I ordered some of the parts for the BMW K1 .I have painted most all of the small red parts.More pics of the cafe as you work on it .I will get up there when I can .Tell Jess and Jeff I said HELLO .

[FC Zach]

Will do. If you do consider stoppin by this weekend it'll just be me Saturday and Jeff and I will both be workin Sunday. I'll try and remember to stop by my storage and pick up the oil cooler for you in case you do visit.

[Garfinkles Motor Works]

What time will you be there Sunday ?

[FC Zach]

Typically we get there around 10

[Garfinkles Motor Works]

I will try to come early afternoon ,see your PM

[FC Zach]

So last week we put the ol Hercules on a diet and stripped it down completely!
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9861&d=1300072824
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9858&d=1300071968

Stripped the wheels down to prep for paint
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9859&d=1300072731
The illusive hub urchin in its natural habitat. Such a mysterious creature.
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9860&d=1300072767

[FC Zach]

This weekend we finally welded the tail section and shaped it some more, painted the wheels, and did a couple other things.

Tail section
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9863&d=1300075942

Painted wheels
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9864&d=1300075966

Made a new splash guard
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9865&d=1300075989

Removed more dead weight (battery box)
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9867&d=1300076056
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9866&d=1300076006

[Garfinkles Motor Works]

Radius or round the corners on the splash guard for a finished look and no place the scrape your hand as you work in there .What color for the frame ?

[FC Zach]

Black

[Garfinkles Motor Works]

My hub urchins only have three legs .What shall I do. I received the BMW parts and started putting it back together ,most of the paint is sprayed .

[FC Zach]

Today Jeff and I got an early start and got some key items done. Next week we 'should' be able to assemble a 'roller'.

Jeff did a damn good job on the frame!
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9980&d=1300679461

Got the wheels spoked and trued, this was PITA! Probably why this is a "lost art"
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9979&d=1300679418

Polished forks and triple trees
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9981&d=1300679482
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9982&d=1300679498

[FC Zach]

Within our showroom it's very possible to stumble across funny little items such as these:

http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9983&d=1300680344
http://rotarycarclub.com/rotary_forum/attachment.php?attachmentid=9984&d=1300680355

[kyle]

Lmfao at Sasquatch footage.

[FC Zach]

Damn Kyle, 1 post since 2008! such a troll :toetap05:

I kidd

[almoststockfc]

woo hooo i wanna go fast

[FC Zach]

http://www.examiner.com/images/blog/EXID23837/images/Ricky_Bobby_I_wanna_go_fast.jpg

[almoststockfc]

post the new pics dammit

[FC Zach]

What new pics!?

[IH8DSM]

Wow jefferies posted

[Garfinkles Motor Works]

Lets see what is going on with the cafe .I havr the BMW K1 up and running but the weather is to bad to ride it to work .

[FC Zach]

It'll be at the gap.

[Garfinkles Motor Works]

No preview pictures, oh well see you at the gap