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Cafe'd Kawasaki W800

Discussion in 'My Bike' started by Lurch, Jul 6, 2015.

  1. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    The side cover ended up getting the same treatment

    IMG_20151222_192214.jpg

    The last couple of days have been masking up and painting the engine black.
    Originally it was going to have silver fin edges, but I wasnt happy the way it was going. Primarily because, being VHT, it doesn't 100% cure until the engine heats right up a few times. So right now the paint is still a little 'glugy'. So I might come back to it.

    10436318_10154409217124256_4582625320339116738_n.jpg 10154101_10154409223989256_8456697670451344911_n.jpg
     
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  2. supamodel
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    supamodel Secret Aaaaaagent Man Staff Member Moderator Supporter

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    The secret I found to doing the fins was actually starting it off with a really gentle file after warming it up with a heat gun for about 20 minutes to cure it (then letting it cool). That starts it off, then you block out some 400ish grit wet and dry (with the paper wet), then go through a few extra grades, e.g. 800, 1200, 2k.
     
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  3. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    I'll let it cure properly through a few heat cycles and give that a go.
     
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  4. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    While trying to decide what colour to do the fairing, I've pulled it off for a while to see how I like it without.

    DSC_0024.JPG
     
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  5. Trumpcard
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    Trumpcard Member

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    I like without
     
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  6. Yedi
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    Yedi Guest

    Looks 1000000% better without the fairing, though if you decide you just gotta have it I reckon satin black would look the goods on there :up
     
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  7. G-relk
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    G-relk Moderator Staff Member Moderator

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    Yeah, I'm digging it without the fairing too.

    If you put it back on, the aforementioned satin black would look good. I still think it would look even better with some chrome-effect vinyl. Make it look like its polished metal like the rest of the bike.
     
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  8. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    Arriving soon will be a replacement headlight. Primarily because I found one with a metal shell, so I can strip and polish it the same as the tank/sidecovers.
     
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  9. jaffa
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    Ever thought about a bug swatter fairing, alla Monster / Thruxton?
     
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  10. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    Like a little flyscreen? Yeah, I have. Again, it'd want it in polished steel to match and it's something thats 'on the list'
     
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  11. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    Mufflers. Finally.
    Still having some issues getting them to seal properly. The exit of the headers aren't a standard size.

    12484795_10154432110809256_37303093872072446_o.jpg
     
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  12. G-relk
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    G-relk Moderator Staff Member Moderator

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    I'm guessing the entry on the muffler is bigger than the exit on the header?

    If so, maybe a sleeve made from an old coke can, plus some exhaust sealant will do the job?
     
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  13. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    It came with sleeves. Bit it's half way between two of them. I got better clamps that came with it, but going to have to go look for even better/stronger ones
     
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  14. G-relk
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    G-relk Moderator Staff Member Moderator

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    Stack one of the existing sleeves with a coke can to get half-way between the two?

    Otherwise, rip the headers off, take them to an exhaust shop, and get them to flare the ends out to the right diameter. Wouldn't cost much.
     
    Last edited: Jan 8, 2016
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  15. Jazz
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    Jazz Member

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    I have no idea what you guys are talking about. I think it looks great.
     
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  16. supamodel
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    supamodel Secret Aaaaaagent Man Staff Member Moderator Supporter

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    Looks great doesn't mean it seals great ;).
     
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  17. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    I got it to seal. Using just a one sleeve and adding fairly wide slots into the mufflers to clamp down on. Then some small tack welds to seal up the slots and A LOT of high-temp gasket silicon/goo/stuff.
     
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  18. supamodel
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    supamodel Secret Aaaaaagent Man Staff Member Moderator Supporter

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    Nice. Was gonna suggest spinning up some mild steel adapters but good it is sorted :).
     
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  19. G-relk
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    That'll do! Can't wait to see (and hear) the bike after all the work you've done!
     
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  20. Lurch
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    Lurch Capt. Sense of Direction Administrator

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    Constructive day in the shed.
    Picked up a (fairly beat up) triple clamp cover from an old Z750 from Joes. Gave it a quick coat of paint and re-did the lettering in silver. It was only a quick job to get a rough idea what it'd look like.
    I like it; so I'll be ordering a good one now.
    Also painted the headlight shell. I did get a metal one, but I have no idea what kind of steel its made of (Supa will probably know) but its really dark and just couldn't get a shine on it. But the black looks pretty good anyway.
    Also made a quick cover/guard thing for the front. Still needs polishing, sealing, and mounting properly.

    DSC_0035.jpg DSC_0036.jpg DSC_0034.jpg
     
    #60