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Jrkk's 1100 cafe build

Posted: 20 Jan 2018, 20:46
by jrkk
Hi all.
New member, Jouni from Finland has registered to the zone.

Not sure if you guys are into cafe racers, but zephyrs anyway.
My 1100 A1 was very good and original condition, when I buy it last summer.

I have always wanted to build something that looks like Z900 from -70's but kind of a newer technique.
So I find this Zephyr's that is retro look, but little a bit newer technique.
So here is how it looks when I buy it.
20170728_155214.jpg
Like I said, I'm into cafe's, so first step was clipons and different headlight.
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This first state was quite ugly, but it was a starting point for me to build a cafe racer.

My goal is to build it, so it can bring back to original, so I have been buying different kind of parts to remake, like seat and tail cover.

We have lot's of snow here now, so I have couple of months time to build it, and I'm going to continue it next winter.
I'd like it to have usd forks, laced rims and stronger swingarm, but that all have to wait till better time (and money).
This winter I'm going to finish the front and rebuild tail section.

Because I don't know your reaction to cafe's and a rape of an zephyr, I will not post anything more at this time.
Also, I'm sorry for my language, but I think that all of you are clever enough to understand my misspelling.

Greetings from snowy Finland
Jones.

Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 20:32
by jrkk
Next thing was tail section.
I found cheap used seat from ebay, tear it down and cut away about 120mm from middle, just before point where it start's to rise.
Welded back together.
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In here, tail is also cutted about 120mm.
Subframe cut is done so, I can install original seat and tail back, if needed.

Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 21:53
by jrkk
Next was foam shape and re covering.
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Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 21:58
by jrkk
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Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 22:11
by jrkk
Then the undertray.
Cut some and add some.
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Tail light
20180112_183550.jpg

Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 22:23
by jrkk
I wasn't happy to my new headlight bracket, it was too long and I decided to make shorter ones.
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heavy hand milling..
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Re: Jrkk's 1100 cafe build

Posted: 21 Jan 2018, 22:31
by jrkk
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Painting was not so good, have to learn to anodize some day.
Also new levers, grips and koso speedo sits there
20180106_173359.jpg

Re: Jrkk's 1100 cafe build

Posted: 22 Jan 2018, 07:25
by Shedman
Hi jrkk, wow! :o You are a very talented guy! I love how you do this work yourself. This is going to be a great looking bike when it is done.

Re: Jrkk's 1100 cafe build

Posted: 29 Jan 2018, 18:19
by jrkk
Thanks, Shedman.

New rearsets from china came, and I started to design brackets.
Pegs are from Neverland racing and they are for GSXR. They cost only 69 €
and I was suprised how good quality they are.
20180127_010828.jpg
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Brackets are not ready yet, need some finishing.

Re: Jrkk's 1100 cafe build

Posted: 29 Jan 2018, 18:56
by jrkk
One more, I drill more holes to them, so I can adjust all possible positions. Previous image show rest of those new holes.
20180127_010746.jpg