78 XS400 Mach1 Cafe Build

[Spitfire_X24]

Some more progress on cleaning, man this is painstaking. The PO had painted some items black and some items silver rather than clean it. So stripping the paint is going better in some areas than others. I'm starting to waffle on whether I should "blackout" the engine like I had planned. The cleaning turned to polishing and the polished covers are looking pretty good.

 

[Spitfire_X24]

Engine is completely cleaned and ready for installation when the time comes.

 

[Spitfire_X24]

I got some work done on the frame as well with my new MIG.

 

[Spitfire_X24]

An update, I worked on building a seat pan and a rear hump yesterday. It's coming along, but a long way to go to complete it yet.

 

[spectra]

You running gas with the welder ? if not get a bottle and ditch the inner shield wire.............

 

[Spitfire_X24]

No gas yet. If set up right you can actually run a pretty decent bead with the flux core. Just a little more cleanup. Used to run mostly flux core with a cover gas back when I was welding full time.

 

[spectra]

No gas yet. If set up right you can actually run a pretty decent bead with the flux core. Just a little more cleanup. Used to run mostly flux core with a cover gas back when I was welding full time.

Yes I run 71T1 with gas...........it runs great...........but flux core by itself sucks its just to brittle for me............and the splatter yeah it sucks...........

 

[Spitfire_X24]

Sorry I haven't posted an update in a while. I was tinkering with an idea for a custom made tail/signal light setup. And I couldn't finish the back panel of the rear hump until that idea was vetted and completed, I've been designing, building, tinkering, starting over and then building again for the last month on it. I sure hope the final result is as good as I hope it will be. I'm trying to mimic the look of the rear of my Mach1 in the design with the triple angled tail lights and then a third brake light above it. I think I got it...
Pics to follow....

 

[Spitfire_X24]

 

[Spitfire_X24]

Thoughts?
Obviously some finishing work to be done yet, but once i have the red LED's wired in behind the Acrylic blocks I think it should look pretty good. It certainly matches the look I was going for in somewhat replicating the rear of the car.

 

[xschris]

I have never been a fan of small lights on the back of a bike. It's hard for others behind you to tell what is going on. Lots of people complain about the stock setup but there is no mistaking when one it turning or stopping. I know in some states bikes with non-DOT approved light will not pass inspection. Just be careful.

 

[Spitfire_X24]

They are super bright. I made sure of that.

 

[amc49]

The inspection thing may also require light to be seen at a direct 90 degrees to the side as somebody next to back of bike in the next lane cannot see light thrown backwards, the box edge lip there will block it sideways. That is a failed light assembly in Texas. What fails so many LED setups, they are too narrow in dispersal (many are only 15 degree) and then you stand to the side and can barely see light while straight behind it blinds you. Look close at your Mustang back again, the outside lens segment wraps around the corner specifically to take care of that.

 

[Spitfire_X24]

I have the outside of the lenses frosted so it illuminates that surface, and they stick out the rear of the bike far enough that you are able to see them flash at 90 degrees from the side. I should be good in that regard.
This bike also has an active title, so an inspection will not be required to put it on the road.
What I didn’t want to do is put on the same LED hoop everyone is getting off of Amazon. I wanted to try and build something completely different.

 

[amc49]

I know it sounds like nitpicking and trying not to but flashing is higher intensity, they have to be clearly seen on the lower level of just lit up as a simple side marker light. I had LED on the back of my 550 and blinding when dead behind but when you looked directly from the side in the dark it was barely lit up, I easily conjured up thoughts of someone looking too quick to change lanes right into me and a common biker killer. So I added two more bulbs turned sideways (one on each side) and that fixed that about 500%.

Sorry if it seems I'm hassling you, certainly not my intention.

 

[Spitfire_X24]

Not hassling at all. All good.
I’m learning and experimenting as I go along. I tried about three different setups before I settled on this one. Different shapes, sizes, polishing and frosting until I landed on this. The creating something from nothing for me is the fun part. Experimenting with something until you get it right, the fun is in the art, and the struggle is in getting it functional.
I tested it with different locations on the LEDs and took a video in my brightly LED lit garage and I was very happy with the result. Because of the frosting on the sides it really reflects the light out the side. Had I left it shiny it would only shine out the back.
I have a video on my Instagram if you want to take a look.

 

[AmbientMoto]

Enjoying this build...

 

[Spitfire_X24]

Sorry, it's been a while, I've made some progress over the holidays, just haven't posted any pictures. I have the tank, headlamp bucket and bezel, as well as the rear hump painted and complete. I will be posting some pictures soon.

 

[Spitfire_X24]

Alright, so I managed to find a place that would match my paint color from my Mach1 and then I finished it with a 2 part chemical resistant matte clearcoat. This was my first crack at bodywork and painting something at this level. It had it's challenges, and it's not perfect, but all things considered, I'm pretty proud of it.
The first pics are still wet, so the matte hasn't dried yet. I also painted the chrome fuel cap flat black to match the shaker hood scoop on the Mustang.

 

[Spitfire_X24]

Up next, finish the frame modifications, add the electrical pan, paint the wheels and front suspension, figure out what to do with the headlight mount and speedo etc...And then the wiring....