Project Cafe Rocket 686 begins. Finally!

[edfmaniac]

Well Grahams got my fork parts here in the 5 business days promised so the project is moving forward again after a long unwanted pause. Evidently my mechanic was lead on a few wild goose chases before I told him about Grahams carrying the Skorpion parts.

I decided to go with a different fuse block but this one should do the trick. It also has a built in relay and the system is very flexible.

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[Srinath]

This looks like a receiver soft start board.
What exactly was it and where you get it from ?
Cool.
Srinath.

[edfmaniac]

It's a fuse block with built in relay. You choose the amperage of the fuse for each line and then choose between the constant on, or the switched posts, depending on what you need and how it's set up. http://www.fuzeblocks.com/

[den]

Whats the underside of that fusebox look like? If its bare solder contacts i would be temped to seal it up with some nice CLEAR silicone ,, The stuff used in making fishtanks,,

[DAVID THOMPSON]

i gave the web site a good read and there is a note in the faq section about a back plate that mounts
over the back of the unit

looking at it as a power point in my car for the ham radio gear i use when mobile
dave

[edfmaniac]

I still have to cut some more of the seat cowl off to make it have a lower profile as well as move it forward a few inches. This was just my first mock up. The tank will be inch or so further forward and sucked down real tight against the main frame. The final paint on the seat and tank will have to wait until I go for the full restoration so I might try the Plasti Dip technique for this first build. I should be ready to break her in before the first really good riding weather arrives in about 6 weeks.

[edfmaniac]

One last photo before she went to the welders. I should have her back on Monday and really hope that the welder's eye is better than it seemed when I was there to give them some direction during the tacking. The fact that this build means a lot to me was clearly made and I told him that I didn't mind paying for him to take his time getting it right.

[edfmaniac]

The bike is back home and there's good news and not so good news. The sub-frame is strong and very light, only 2 lbs. The not so good news is that the welder was not able to make consistent beads and didn't follow my directions on how to fit the pipe hanger. Not a big deal but it would have been nice to be able to show off the hand built stuff without having to warn them about the weld quality.

Looks like it's all on my shoulders now as far as the rest of the build. Everything except fluids and a few odds and ends are here and waiting to go on the bike so full steam ahead for the next week or so.

[edfmaniac]

Almost ready for wiring.

[droy]

Can't tell from the picture - oil tank location and construction? Also can you walk us through mounting the fuel tank?

Thanks

Doug in NJ

[edfmaniac]

The oil tank is where the battery/airbox used to be. A pic of that tank is on page 4 of this thread. The fuel tank uses the three stock Suzuki RG125 mounting points, two bolts in the rear and a semi-cylindrical horizontal socket in the front that looks like it mates up to a tube. Since the Skorpion doesn't have that tube, I bolted in a piece of aluminum plate that is the right length and will be molding a piece of epoxy putty onto the end that will match the female tank mount.

[droy]

Thanks for that. A few shots of the oil tank fitted would be great when you get a chance.

Great build - thanks for sharing.

Doug in NJ

[edfmaniac]

I'll definitely be posting detailed pics of the entire sub frame area when it's done. The last little bit of welding is being done right now.

[edfmaniac]

Well I found the welder that will be getting all my business in the future. It turns out that the guy who gave me the eight hour quote on welding out the whole sub frame is a real genius and probably could have done the work for less than that. It would definitely have been the right move. He was able to tie in 1/8" plate to that thin walled aluminum tubing with the accuracy of a machine weld. Incredible work if you ask me. (top weld only)

[edfmaniac]

I could clean up the wiring job a little more but I'm tired of soldering already. I'm just happy that everything works, after a hiccup or two, and nothing smoked. My doubts about the size of battery that I chose have been smashed. The bike turns over much faster than it ever did with the old engine and lead acid battery. And that's with no decomp. She gets fuel and fire as soon.