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Member's Restoration & Rebuild Projects Details of member's own projects.

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Old 09-11-2012, 09:20 AM   #1 (permalink)
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I bought a frame.....

....and decided to build a Bonneville T140 Cafe Racer from scratch.

Back in the UK I owned a 1958 Triton but didn't do much to it beyond basic maint'- I had a man to fettle it for me. I've just finished a Honda CB750 cafe racer project (Currently for sale on Ebay, plug, plug) but feel I didn't go far enough with it. Hence this decision.

I've never built a bike in my life but have worked on engines a little. I can't paint or weld- that will be done by professionals. I can bolt things together. And I can soda blast but not polish.

Having got a frame (1979 OIF) I bought a 1975 T140V engine. I'm currently stripping that down and then will rebuild it replacing what needs replacing. So far I've replaced the barrels, valves & springs, valve guides, con rods and pistons plus other bits and bobs.

This isn't going to be a factory rebuild, it's my vision and may horrify some of the "pureists." (Frankly I'm not even sure at this point that I'm going to like it when it's finished)

I've bought one of the light weight lithium batteries and that'll go under the seat hump and I'll proberly tuck the coils under the seat where they were in the original set up but horizontaly (sticking with 2x 6 volt coils). I've bought a great custom modular wiring harness from centech (http://www.centechwire.com/catalog/cycles/cmc1.shtml ) and I'm going with an Acewell digital instrument set up.

Mostly everything is going to be powder coated including the rims, hubs, barrels and even the tank.

I stole an idea off one of the other builders on here and my rear sets are from a Yamaha.

I'll try and stick some photos up next week- a lot of the engine is laid out on tressle tables in the dining room (where else!)- perhaps I should say I'm divorced so I'm allowed to do that kind of thing....
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1979 Bonneville T140- ongoing Cafe Racer project.
74 Norton Commando MkII- next Cafe Racer project.
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Old 09-11-2012, 09:40 AM   #2 (permalink)
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should be interesting.

one problem that you'll have is that the 75 is ( I think) RH gear change and the 79 frame will be LH gear change.

That leaves you with an issue of either changing the engine to be LH gear change or fitting a LH brake to the 79 frame.

I don't know what's easier. ( probably the brake, bearing in mind that I assume you're using rear sets
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Old 09-11-2012, 09:43 AM   #3 (permalink)
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Welcome to the forum! Sounds like a great custom project. WE NEED PIX!!!
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Old 09-11-2012, 12:28 PM   #4 (permalink)
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Sounds like a fun project.

Can I give you a small piece of advice from someone who's made the mistake? Make up your mind exactly what you want it to be before you get much further... these projects tend to evolve as you go along and if you don't know where you're going you'll end up somewhere you weren't planning to go!
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Old 09-11-2012, 01:33 PM   #5 (permalink)
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someone on here a while a go posted pictures of a cafe racer with a left hand rear set operated disc brake.

I have no idea how to find it!
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Old 09-11-2012, 03:13 PM   #6 (permalink)
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sounds very interesting, I will be keeping an eye on the build as I got a work interest in cafe racers n classics.... if you need clocks give us a shout or visit the site we just launched our SMITHS motorcycle gauges on. http://www.smithsspeedos.co.uk/

I know its cheeky but you never know

good luck with the build too
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Old 09-11-2012, 06:42 PM   #7 (permalink)
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My T140 cafe project is based on a '73 frame and engine, but I believe the left side rear brake set-up I came up with could be used on any OIF. (On the shift side, I'm just reversing the lever.) Here is a shot of the basic rearset. I used a shift lever and shift shaft from an old Montgomery Wards Benelli, but lots of other combinations could be used. You can see the brake actuating rod peaking from behind the frame rail.
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Old 09-11-2012, 06:48 PM   #8 (permalink)
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Here is the rod and the rear master cylinder, which is off a Yamaha motocross bike ($8 on ebay!). Note that the frame had to be relieved to allow everything to tuck in close enough to clear the chain,
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Old 09-11-2012, 07:07 PM   #9 (permalink)
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This just shows the bracket I made to mount the master cylinder. It is angled to more-or-less precisely "aim" the brake rod down to the actuating lever.
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Old 09-11-2012, 07:11 PM   #10 (permalink)
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Though it cleared the swingarm anyway, the actuating rod got too close for comfort when the shocks were completely compressed, hence this clearance piece. Incidentally, the alloy SA "bushings" are just for set-up purposes.
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