I knew I wanted to build a cafe racer type bike when I started looking at the twins and I knew I wanted to do all the work myself. I had to learn a few thing, watch a few videos, some practice, but the bike has come a long way and has really met all my goals thus far! Follow along on my custom 650 Project. Here's a list of all the work done so far with product links, information and much more.
I measured the subframe and found a Stainless Steel Hoop on Amazon matching the specs of the stock subframe. I bought a welder at Harbor Freight and practiced in my garage for a few weeks. Once I felt comfortable, I gave it a shot. A little light grinding with the flap disc, some sanding and some VHT Gloss Black Roll Bar and Chassis Paint gave the new hoop a factory look. I didn't want to have a fender stick out past the hoop so I made a template from cardboard and traced it on to a steel plate. I cut, sanded and smoothed out the plate for paint. I also welded in the spacers needed for the mounting points which also required a tab to be welded on the inside of the hoop. I painted everything with the same roll bar and chassis paint mentioned above. The finishing touch was a rubber edge seal around the plate. It gives the rear a nice finished look and blocks any light from passing through which helps in photos.
I started to black out some of the parts starting with the heel guard and intake covers. I used the same VHT Gloss Black Roll Bar and Chassis Paint that I used on the custom hoop. I wanted to go a little further with the headlight bucket and front fender. First, I cut the fender down by cutting the ends off and tracing them on what was left of the fender. I cut them with an angle grinder and a cutting disc and then sanded and smoothed with a handheld electric sander. I prepped the bucket, ring, fender and bracket for paint using a method on YouTube, Professional quality paint job for under $100. He list all the supplies and materials on his video page, this includes all the prep and painting supplies. He uses a green in the video, I used the Dupli-Color Black Magic Pearl Volkswagen Perfect Match.
This always looked so slick to me, the contrast and just the overall classy look. This one took some patience and a steady hand. There are a lot of old school painters and pinstripers who are really good at this. There's also a good amount of tutorials out there. I used Testors Gloss Black Enamel, some brushes, Q-Tips and acetone/paint striper. After painting in the letters, I used the Q-Tips and acetone to clean up the edges. After all the letters were done I used some Autosol Light Metal Polish to clean up the rest of the case which I also use in my regular upkeep.
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