honda xbr500 cafe racer - we only have 2 months to completion

As Pud says, you should be able to get that alloy welded, if not then it's E-bay for a replacement.

i aint wallowing in your misfortune mate but its reasuring to know that these things dont just happen to me

easy fix tho bit of paper mashay and some silver paint should sort it ;

seriously whats the parts availability like on them ? they are quite rare but there must be someone breaking one

Try Peter at DK Spares. Pretty sure they will be able to sort you one.

Have tried every where & every one & it's either a full engine or nothing.fortunately
My eldest lad knows a bloke who is reputed to be one of the top alloy welders in the uk. This guy is a genius , he runs welding workshops-all types, as well as designing & manufacturing kit cars, it's going to him on Monday to be welded & then back to the polishers again.
Next Friday the engine mounts are back from the chromer so souls get the engine in & rebuild the forks with new seal & oil

Try

http://www.ebay.co.uk/itm/HONDA-XBR500-GENERATOR-CASE-/270825419258?pt=UK_Motorcycle_Parts&hash=item3f0e73f1fa

or

http://www.ebay.co.uk/itm/HONDA-XBR500-GENERATOR-CASE-/270825419492?pt=UK_Motorcycle_Parts&hash=item3f0e73f2e4

pauliexjr wrote:

Try

http://www.ebay.co.uk/itm/HONDA-XBR500-GENERATOR-CASE-/270825419258?pt=UK_Motorcycle_Parts&hash=item3f0e73f1fa

or

http://www.ebay.co.uk/itm/HONDA-XBR500-GENERATOR-CASE-/270825419492?pt=UK_Motorcycle_Parts&hash=item3f0e73f2e4

cheers mate never saw those
the £45 one arrived this morning & is now on its way to the polisher

Glad to be of help, insomnia and curiosity are both a blessing and a curse!

thanks to pauliexjr i bought a new case for it instead of having it welded, the crack ran down most of the inside of the case.
its arrived & gone straight to the polisher, should be back next tues / wed
the chrome engine mounts should be with me by monday so should get the engine in by tuesday

Didnt get much done last week as we were very busy with the cafe racer seats we sell, brought 3 new types out & selling loads.
Had another look at the carbon seat we made for this bike & it looks too wide at the back & a bit bulky too, so i got my lad who is an ace plug maker(does all ours) to make a seat plug especially for this bike he only had 1 day as he was needed to make seats that have been sold.
whilst he was doing that i prepped the tank for painting ready to make the moulds.
This is what we ended up with after a bit of black 2k paint. mould making started today.
I tried to get new swinging arm & wheel spindles from honda as these were a bit grotty,but they are no longer available so had a word with my chromer who plated the nut ends, not only that but he also plated the end that pokes through the nut just before the thread (i never asked him to - but thats one of the reason i use him)
The chrome engine mounts came back on saturday so we skipped lunch today to have a little play, just waiting for some more bits coming back from the polisher & the moulds to be finished tomorrow then we can make the carbon bodywork

one word " impressive "

Wasn't sure about the gold frame TBH, but, teamed with black bodywork? I think that is going to rock. Looking forward to more piccies!

nice..ly ......coming along

the new engine casing is back from the polishers & on the bike.
the bike is back on its old wheels while the new spoked ones are being rebuilt, had to put it on the wheels so we could get the right level for the tank to fit.
not got that much done actually on the bike this week as we have been busy making some moulds,
for it these are now ready to make a few carbon bits for this bike they include seat )see picture of it now made), tank,chain guard, headlight bowl & fuse box cover
this is how it is looking at the moment

that is looking great mate

I love the frame color.
I'm also working on a CR based on a XBR.
I you need parts that you can't get, check this out (as new member I can't write complete links for a week)
bike-teile.de
You need to speak german (or get somebody who does) but there's a huge selection on XBR/GB parts.
I'd love to see more pics as the job advances.

grrrreat mate

WHAT DO YOU GET THIS TIME OF YEAR WHEN EVERYONE GOES ON HOLIDAY?
SOD ALL DONE ON THIS BLOODY PROJECT!!!
The polisher has some parts & more importantly the rims he is away till tuesday,The guy that builds my wheels goes away tomorrow so cannot get my wheels done for at least another week & the chromer has gone away for a week whilst he still has a few bits from the bike that i need.
The 2 months is up next week & due to these spiteful people taking holidays just to slow this project down, i wont make it. but it doesnt matter s its my bike now not the customers.
had a few disasters this week
1 put the rs rear hub in the parts washer to get all the solid grease off & a great chunk of e metal fell out around one of the bearing mounts & noticed one of the cush rubber mounts had been glued back on - into the scrap ally bin
2 couldnt find another rs rear hub or wheel anywhere so ended up buying a cb350f cb400f wheel from the early 80's
3 that cost me another £60
4 the front disc i had was warped (cost me another £22 for 2 mint ones delivered)
5 lost the charger for my digi camera so can not post any pictures this week
on the plus side some things have gone well
1 the new wheel does not need any machining, offsett is perfect just need to make some spacers
2 found a small company that will make me a sprocket for the cb wheel in xbr pitch within 7-10 days for a good price
3 got the front hub spaced up & painted it in the same colour as the frame
4 bought new braided oil lines, my lad uses a place who is very good on price & fastens them to the original connector- looks clean & new but standard
5 finished tank, front mudguard rear & mudguard moulds & made a carbon chain guard
6 polished oil tank & breather fitted back in the frame
we are getting there slowly,
7 also shaved 2mm of the caliper carrier so everything is aligned & working on the front.
we are getting there slowly,
will either get a new charger or new camera next week & post some pics

and I thought it was just me who has bad days

its a commonly known fact that if its a homer, it'll go wrong,


a lot.

worth it in the end though.

beekeeper wrote:

its a commonly known fact that if its a homer, it'll go wrong,


a lot.

worth it in the end though.

not a simpson is sight here mate
not a bart,marge or maggie, here at all
& Definitely not a homer!!!
sorry couldnt resist

didnt mean to offend.

common saying round these parts meaning private job other than customers.

No offence taken mate, I new what you meant but couldn't resist taking the pi@@

sorry for the lack of posts, i have not been skiving just very busy.I am in the process of getting 2 websites sorted one for the ducati carbon & the other for the cafe racer parts, lots of photo taking & adding items to the data bases.
i decided that as everyone else was on holiday & i couldnt get my parts so i wouldnt get much done on the bike & business was quiet i might as well join them. So i had a few days off too
back to work now & still waiting for bits to turn up, so i thought i would tackle the wiring, which was a right mess loads of twisted wires in insulating tape, have removed the indicator wires & relays relocated all the components under the seat hump & just about sorted it. All soldered with heat shrink over the joints -took bloody hours.

The body work is coming along nicely, the tank cover came out of the mould today, the seat unit, mudguards(front & rear), & chain guard are all made just need paint & lacquer.Tomorrow i am making the wheel spacers at my mates machine shop & hopefully collecting the spoked front wheel along with the front mudguard brace from the chromer, early next week we should have the front end all together & on the bike.

that is looking sweet

well i'm impressed.