Author Topic: Cafe Build of a C10  (Read 1430 times)

Offline sport rider

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Cafe Build of a C10
« on: December 28, 2018, 10:20:25 am »
I thought I'd start a separate thread than my intro thread to post more about my cafe project.  attached is a prototype pic, but I still have a LONG way to go before I call this one done.  I picked up a $350 donor bike for starters.  it showed signs of being dropped like the fairing cracks at the mirrors, and some minor cracks on the side panels.  however, no signs of  being down hard.

I have a ZRX front end and meanstreak rear wheel to set it up with 17s front and rear.  I'm using the stock ZRX bars for now, but will likely replace those as I get closer to completion.

for now, I plan to use the stock tank.  that might change before it's all said and done, but for now, it's a low budget build.  I have removed the rear frame section as well and will try to cut down the stock seat to an appropriate look.  I'm going to have to either fab a seat pan or see if I can source something that will work.  for a prototype, I chopped down the stock seat.  it looks good for a concept, but needs proper finishing to look right.

the coolant reservoir had already been relocated by the previous owner.  I plan to fab an inner fairing.  might be able to use the stock one with some modifications.  the battery area will be covered with an oval numbered disk for some "authenticity".

still thinking about the rear shock.  perhaps a ZZR1200 or an aftermarket progressive HD.  I mounted one of those on my sidecar rig and it's pretty stiff.  the 05 model has the ZZR on it.  since it's primarily for 2-up riding, I might replace it and move the ZZR to the cafe.

right now I need an ignition switch and gas cap with keys.  the previous owner said he would mail the key, but have tried several times to get him to send it to no avail.  could get a locksmith.  we'll see.

I also need a right footpeg and bracket.

if anyone has spare parts, holler at me.

Offline DC Concours

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Re: Cafe Build of a C10
« Reply #1 on: December 28, 2018, 10:33:22 am »
That already looks nice. How did you remove the rear wheel fender and how is the seat supported?

Offline sport rider

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Re: Cafe Build of a C10
« Reply #2 on: December 28, 2018, 02:11:08 pm »
rear wheel fender is just a bunch of bolts here and there to remove it.  the rear frame section, which is bolt on, is removed too.  Right now the seat is just sitting on the frame that is left.  I'm thinking I'll use the bolt holes where the rear sub-frame connected to use quick connect pins to hold the seat on for a final solution.  I'm going to have to fabricate a hoop which will connect at the same spot as well.  that will support brake lights, turn signal and license plate.

Offline kzz1king

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Re: Cafe Build of a C10
« Reply #3 on: December 29, 2018, 08:46:37 am »
Looks like a fun project. Great platform to build on
Wayne
2010 CONCOURS
1974 Z-1

Offline sport rider

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Re: Cafe Build of a C10
« Reply #4 on: December 19, 2019, 10:15:52 am »
Old post resurrection.  I've basically just been tinkering with the bike, fixing odds and ends over this year.  I've got all the basics going and am down to the seat and support development.  I've bought some steel pipe to bend into a tail section.  from there I plan to figure out a tail section cover and then move back to creating the seat/pan/cover.  I'm hoping that I'll have some time to devote to it over the winter months.

attached pic is most recent of where things sit, but I did have to replace the tank, so paint is still a bit up in the air.  I'm actually thinking perhaps going with a medium blue color.  but I have some seat pan configuration ideas in my head, so hope to be able to make the progress.

Offline DC Concours

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Re: Cafe Build of a C10
« Reply #5 on: December 19, 2019, 04:59:42 pm »
Good going on the project. I like the orange paint. Keep it.

Online gpineau

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Re: Cafe Build of a C10
« Reply #6 on: December 19, 2019, 05:03:17 pm »
Mine is cut off about the same place as yours but my seat is also cut at the same place.  For the license plate , tail light, and turn signals I made a bracket out of homedepot angle iron and steel pipe.

The side fairings I got for $38 including shipping. The guy said they would fit so I am going on faith.
I found another pair but the guy wants $50 for them.

https://www.ebay.com/itm/Concours-Side-covers-ZG1000-A8/301839573250?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D01223620fc024750a29b99b578177d91%26pid%3D100675%26rk%3D2%26rkt%3D15%26sd%3D223688878261%26itm%3D301839573250%26pmt%3D0%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A3531dbdc-22bb-11ea-bd15-74dbd180e886%7Cparentrq%3A2097982c16f0a860d2d3ab46ffb5ac4a%7Ciid%3A1
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Online gpineau

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Re: Cafe Build of a C10
« Reply #7 on: December 19, 2019, 05:22:08 pm »
Have you taken it for a ride yet? Do you have any problem with that wrapping around the tail pipes? Only one of my pipes had it and it smoked like crazy and gave off strange smelling vapors.  I ended up cutting it off.

Also I found an air box for mine so it looks more stock (ish)

I let mine sit for a long time but now I am getting anxious to get it finished. As spare time and money permits.
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Offline MAN OF BLUES

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Re: Cafe Build of a C10
« Reply #8 on: December 19, 2019, 06:43:00 pm »
the fabric wrap on the tubes, just holds moisture, and will eventually lead to spiral splits on the pipe, from migration where it's wrapped with the wire.

The pipes, being an alloy of Stainless, don't really need that... it' just something that cause another failed component, especially when you don't even have mufflers, keeping the heat in... :rotflmao:

Rock on man, I like the Orange paint...

oh, take a razor knife to those fork "gaitors" and cut them in half... the look like "rumple forskin"...  ::) 8)

you are on the way tho...

30 YEARS OF KAW.....

Offline sport rider

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Re: Cafe Build of a C10
« Reply #9 on: December 20, 2019, 10:08:58 am »
Have you taken it for a ride yet? Do you have any problem with that wrapping around the tail pipes? Only one of my pipes had it and it smoked like crazy and gave off strange smelling vapors.  I ended up cutting it off.

Also I found an air box for mine so it looks more stock (ish)

I let mine sit for a long time but now I am getting anxious to get it finished. As spare time and money permits.

no particular problem with the wrap except that I've gotten some coolant and oil spilled on them which smokes a bit when they get hot.  I'm likely going to remove it.  just something else to do.  :)

I'm probably going to go back to the air box.  I've got three sets of carbs and one of them will go off to Steve for a makeover.  it's time to get it running "right".

Offline sport rider

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Re: Cafe Build of a C10
« Reply #10 on: December 20, 2019, 10:12:05 am »
the fabric wrap on the tubes, just holds moisture, and will eventually lead to spiral splits on the pipe, from migration where it's wrapped with the wire.

The pipes, being an alloy of Stainless, don't really need that... it' just something that cause another failed component, especially when you don't even have mufflers, keeping the heat in... :rotflmao:

Rock on man, I like the Orange paint...

oh, take a razor knife to those fork "gaitors" and cut them in half... the look like "rumple forskin"...  ::) 8)

you are on the way tho...

Wrap will come off at some point.  just bigger fish to fry at the moment.  the big problem with the fork protectors is they are old and rotted.  they are going to get replaced.  Perhaps pink.  :)


oh...and muffler is nicely placed on the other side of the bike.  doesn't it look cool having this side more "naked"?   :thumbs:

Offline gPink

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Re: Cafe Build of a C10
« Reply #11 on: December 20, 2019, 03:24:58 pm »
pink is good  :)
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Offline MAN OF BLUES

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Re: Cafe Build of a C10
« Reply #12 on: December 20, 2019, 03:44:57 pm »
Wrap will come off at some point.  just bigger fish to fry at the moment.  the big problem with the fork protectors is they are old and rotted.  they are going to get replaced.  Perhaps pink.  :)


oh...and muffler is nicely placed on the other side of the bike.  doesn't it look cool having this side more "naked"?   :thumbs:

groovy.... need pics of all the sides, I like it...  :thumbs: :thumbs: :thumbs:
what exhaust did you use, to be lefty mounted??  I have a set (new, un used) Ontario pipes, but they are right hand side....

Oh, and I give thumbs up on the Pink, fork gaitors.... (actually had a red set, that bleached out to Pink, on my '74 KX450 MX bike... took a lot of chides from my pals when I was racing...  but none of them ever "saw" the front of that bike... jut the clods of "mud grenades" I launched at them thru each moto...) :rotflmao: :rotflmao: :rotflmao: :hitfan: :stirpot: :hail: :hail: :rotflmao:

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Online gpineau

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Re: Cafe Build of a C10
« Reply #13 on: December 21, 2019, 04:29:23 pm »
I like that you were able to move you pipes to the other side. I bought a couple stock mufflers just because it was so loud.  I been working on mine today, cleaning up the loose wires and hoses. Stole the mirrors off my magna. The look better than those sticking our the ends of the handle bars.

 I was standing back looking it over and it just didn't look "right" to me.  I put the tank and the seat on it and had another look and it still looks funny. That huge tank and tiny seat make it look like a dwarf with a hunch back.

  I am thinking of extending the frame back to at least the middle of the back wheel. What do you think?
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Offline sport rider

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Re: Cafe Build of a C10
« Reply #14 on: December 22, 2019, 09:40:49 am »
I understand everything you are saying.  the single side tube can be homemade with an extra set of pipes, some cutting and welding.  it's a home-made deal as there's no aftermarket that does it.  Per others, this does NOT improve performance (and might even lessen it), but there's plenty of power for my needs and mine is as much an effort of looks.  (same approach for the pods i'm working with). 

you might try to find some aftermarket mufflers which are upswept rather than the stock ones.  I had an aftermarket can which I attached to the frame using one of the connection holes on the frame.  (can provide a pic if you want).  I bought it online to specific size and had a local muffler shop bend it to the angle which matched what I had the muffler set to.  it could be easily done on both sides to make a dual upswept exhaust.  I think that would look good if you got the right angle set.

as for the seat, I year you and am struggling with design on that part too.  I found out a few things.  first, I believe the frame tubing is slightly over 7/8 inches internal diameter.  I'm able to use one of the handlebar ends to slide inside it.  I am planning to cut the 7/8 ends off the stock bars and use that as a "slug" to slide into the frame tube and weld in place.  I've sourced some pipe which is 7/8 ID and 1 1/8 OD.  I plan to bend this into a loop for the back end which will align with the frame width.  then the 7/8 handlebar tube will slide into that and weld together.

once that part is done, I plan to fabricate a large hump on the back of the loop.  making it sufficiently large so as to match the look of the large tank.  hopefully that will balance it out a bit.  it's all about the look, so will see.  I'm including here a pic of a "model" I'm going off of.  I think it looks reasonable.  I know the guy which did this did a fiberglass build.  Once all that is done, I plan (I think) to use a cut down version of the stock seat pan and build up foam to match the angles I have in mind.  This can be custom covered.  I just need to work out a plan to attach the seat pan, using the front slide-in and fabricating a simple clip system for the back end of it.

once all that is done, I'll fabricate some simple mounting plates for the rear brake light, signals, and license bracket.  the guy who built the one in the pic used the original brake light and fabbed the rear hump around it.