Project Sabre Cafe Part 17

This week I received the Emgo fairing that I ordered and mounted it on the bike. At first I was unsure about it but it’s beginning to grow on me. I think it will all come together when everything gets painted. The project is down to the details now and I’m almost done with the fiberglass work. Next week I’ll be melting out the foam from the tank, installing the fuel petcock and fuel lines then sand, prime and paint the tank and seat. Once painted the seat pad will be made and installed then comes inspection time and a trip to DMV for registration and plates. I hope to be done in time to drive it for a couple days before I take it to the Bull City Rumble in Durham Aug. 30th. That’s the plan anyway…..

Keep on hackin…

Project Sabre Cafe Part 16

I finally took apart the front calipers and did a full rebuild. Things weren’t pretty inside. Lots of gunk and a seized floating pin, which was causing most of the drag. I’ve been adding more fiberglass to both the seat and tank and they’re shaping up great. The battery finally has a new home under the seat and I’ve got some mailbag goodies!

Keep on hackin….

Project Sabre Cafe Part 15

I made a lot of progress this week! I worked on the tank, seat, tail light and I installed a unique coolant reservoir. My latest shipment of fiberglass arrived today so next week I can get a lot of glass work done. Here’s this week’s video and a few pics of the bike as it stands today.

Keep on hackin…

Project Sabre Cafe Part 14

This week was spent on the LED indicator lights and a new key switch mounted in a panel on the old handle bar bosses. I had to fabricate a panel from some sheet aluminum to mount the LEDs on and wire them up to the harness. I used a handy online LED resistor calculator to help determine which resistor was required for each LED. Adding a resistor to LEDs is required to keep them from burning out. I’m supplying them with 12 volts and they’re rated at 2.5 – 3.5 volts. The resistor limits the current flow and will get a little warm so it’s important to use the right “ohm” value. The term “ohm” is used to describe the amount of resistance to current flow the resistor has. Resistors are color coded with their ohm value. Here’s a handy resistor color code guide to help with deciphering the code.

I really like the new LED panel. It covers over the unused handle bar mounts and it has a nice clean look that finishes off the instruments nicely.

I also did a little modification to the seat. I added a little more to the bottom at the rear. It just seems to balance out better and it hides the rear subframe a bit more.

Till next time, keep on hackin!