FABRICATION on Yamaha Virago Café Racer: RALLYE Headlight + SHORT Kickstand

what's going on guys i'm tristan duran and this is my yamaha virago that i'm transforming into a cafe racer if you're new here welcome to my channel if you've been here before well welcome back on the last video we put the front end from the yamaha r6 on the frame of the virago so it's mechanically sound but i'm still missing a few things to button up that entire front end i'm missing a throttle i'm missing the switch assembly with the start button i'm missing on the other side the other switch assembly with the blinkers the clutch lever the handle and then the ignition switch and the headlight maybe your horn blinkers all of that then that's what we're gonna do today and let's not forget the kickstand because the bike is on it right now and you can see how straight it is it's about to fall so i need to shorten the kickstand and do some welding i want to start with the simple things like the throttle the switches on both sides the clutch lever the ignition switch because when i've got all of that positioned on the on the front end it's going to be easier for me to position my headlight do some fabrication make my bracket and all that to have a really good calf eraser look so let's get to work [Music] i was taking the switch assemblies from the oem front end on the verago and i noticed that some parts were rusted so i put them in rust remover it's gonna stay there for like two hours minimum so meantime what i'm gonna take care of is the kickstand [Music] so i don't really know how much i need to shorten that kickstand what i did now is i removed the flat at the bottom of the kickstand and i measured it the thickness here is around seven to eight millimeters depending on where i measure so that means that the length of the kickstand when it touches the ground is shortened by seven to eight millimeters i just tried on the bike i feel like it's not enough i still need to remove a little bit maybe the sweet spot is ten millimeters i'm not sure but this is what i'm gonna try i'm gonna remove three millimeters more here try it on the bike and see how it goes so [Music] do [Music] so i really took my time and went step by step to cut the kickstand so that's what it looks like right now i cut one two three four five times and then this is 30 millimeters that i cut from the kickstand three centimeters the flat right here i put it really flat i removed everything so it's super smooth so i got my marks here and here and i got the same over there on the kickstand so i know how to position my kickstand on the flat when i'm about to weld so i got the right position and i'm not doing anything that when it's finally on the bike doesn't look as good as i want so i'm gonna get the welder and get on welding [Music] and it actually went really good even though i'm very new to welding welding on steel is pretty easy to me so i was doing my beads my kickstand is done i did the priming the paint the clear coat now the clear coat has to cure honestly the paint is the most time i spent on that project it's not even the welding it's the painting so i'm gonna wait for that to cure and meantime what i'm gonna do is i'm gonna take care of the controls here so we talked about the switch assemblies and i was removing some rust on some of the parts this is done so i'm gonna put those switch assemblies on the handlebars they're right here and i'm gonna hook everything up and when that's done i think i'm gonna put the ignition switch on the triple tree and then get them [Music] moving [Music] oh [Music] and the throttle choke and clutch are all hooked up on the bike but when you look at it from the side you can see those cables are really protruding from the front of the bike right here especially this one that is the clutch cable so it's just too long now we used to have handlebars on the verago that were pretty high up so you need to reach those levers all the way up here and now with the clip-ons we got that look that i love with the clip-ons really low on the bike but we don't need that length anymore so we're gonna need to shorten the cables i'm pretty sure i'm gonna have to do the same for the throttle right here definitely for the clutch maybe the choke but that's something that i'm gonna do on another video not this one stay tuned for this i recommend subscribing to the channel or at least liking the video it really helps me what i'm gonna do now is i'm gonna take care of the ignition switch it's on the virago triple clamp i hope it fits on the r6 triple clip but we're gonna find out [Music] nature [Music] [Music] [Music] so that wasn't too bad i got my ignition switch on the r6 upper triple clamp right here the big difference between the virago and the r6 is really the center to saturn distance for those two bolts here on the ignition switch so the r6 is a little bigger and the virago is a little smaller so i just had to file a little bit nothing major and it looks like that right now it's very easy five minutes the thing is when i want to tighten those bolts if i do it all the way it's going to bring my ignition switch sticking out a lot on that triple clamp not a look i want i really want something that not completely flush but maybe like one or two millimeters kind of like this right here so when it's like that you can tell there's a big gap here and that's where i need to have spacers i don't have the tubing i need for that right now so i'm gonna order the tubes i'm going to cut them to length to make myself some spacers on each side and then we're going to be good but right now we got everything situated on the front line right here so it's going to help me to then position my headlight and i got a special one [Music] [Music] so you see i have a ready car light i think it's going to look amazing when it's finished on the bike the reason why i picked this one is because it is very very thin so it allows me to really put it between the tubes on the front of the bike so it's recessed and i think it looks really neat like that so i have right now a bracket right here and i need an interface between that bracket and my lower triple clamp and that's what i'm going to make that's my fabrication i need to make and i'm going to use this as a mock-up so this is just cardboard and i can kind of bend it and it's easy to cut with just scissors so i'll make a mock-up of the bracket i want to make when that mock-up is done that means i can cut my aluminum and do my fabrication my welding and then put the headlight on the front end let's go ahead and do that [Music] baby [Music] uh [Music] and that's when i realized i forgot something so i went a little too fast i forgot the front brake line extension on that bracket the black part you see on the screen right now is the oem yamaha r6 bracket to hold the horn and the front brake line so i need to put this extension on my mock-up that's the reason why i make a second mock-up right here it's going to be very fast and then i'll be able to hold my front brake line [Music] and then you see me here holding the front brake line close to the extension just to make sure i got the right angle so now i've got my mock-up and i'm ready to cut the aluminum [Music] foreign and that's what it is so this is aluminum it's pretty thick it's 0.1 inch thickness i'm very happy with what it looks like right now but i need to bend it and i never bent anything that thick before i have a brand new metal break it's still in the crate i need to unpack it and see if it can bend that because i think it's for thinner material so let's try [Music] yes [Music] it's breaking it [Music] oh wow oh it's okay huh not expected [Music] and that's great news that small break bends that type of aluminum i will definitely remember that for the future because i'm gonna have some bending to do but i had a small accident on that extension right here to hold the brake line the front brake line on the forks while that broke off so i'm basically trying to do the same as the oem bracket this is steel and that looks like that right here so i'm gonna keep the same angle between the two this and this and i'm gonna weld them on the aluminum part right here so let's set up the welder [Music] wow [Applause] [Applause] the welding went so fast the last time a welding aluminum was cast aluminum on the frame of the yamaha r1 before that was cast aluminum on the crankcase of the yamaha r1 so this here on clean clean aluminum was so easy so fast i'm surprising myself so i'm very happy with that you can see that i polished it so on the outside you don't even see it was welded it is beautiful very strong now you know the trick i'm gonna prime paint in black matte then i'm gonna apply my matte clear coat and then we can put it on the front end [Music] and the bracket is not cured look at this so i hope you can see the texture on the paint job what i do is i mist my clear coat many many different times it's a lot of coats but they're not full coats very very wet it's really just a mist on the part and it achieves that type of texture at the end you see all those peaks and valleys on it i think it makes the part very interesting to look at it's not a boring flat sometimes i love flat but on this one i wanted something very interesting and i think i think i've got it so it's ready to go on the bike and put the headlight on it before we do that though i remember that i had some comments on the last video saying that because i lowered the front end of the bike with that smaller wheel and the shorter forks that my rake the caster angle on the frame must be too steep now and that my bike is going to be very nervous and i don't know i need to measure that what i do know is that the yamaha virago out of the factory is at 29 degrees on the rake so let's measure it now okay so it used to be 29 degrees now i'm gonna put my protractor on the steering column right here and how much do we have we are at 24.9 let me change the spot here 24.95 24.9 24.9 all right so it really looks like we're around 24 and 25 very close to 25 degrees just as a reference the yamaha r1 and r6 since the inception have 24 degrees rake so basically what we're saying is like it's not too steep it's very good it's slightly more open than a sport bike i got the front end of a sport bike the r6 so i'm gonna have a behavior that's very good and very like a sport bike this is all theory because the rest of the bike is very different the weight distribution on the bike is different but it's it's good to know like it's not alarming i've got a good rake angle i didn't know how much i had and i do so what i can do now is i can put my bracket with a headlight on [Music] [Applause] [Music] so [Music] [Music] oh yeah [Music] so it used to be just an idea in my head and now i see the headlight on the bike it's so spot-on with the look i want to have on my bike i am glad i made that choice so to finish it off i'm gonna put the kickstand on the bike [Music] so [Music] you've got to love when things go so well so the headlight and the kickstand on the bike and this is exactly what i wanted to do today so i still have a lot of work to do on that bike electricity tank re-end that's a lot of things and that's going to be on all the videos i'm very happy with my welding i feel like it's slowly getting better which is encouraging because i'm going to have so much welding to do on all the other projects if you want to see that you should consider subscribing to the channel activate your post notification this way you know when i post a new video if you like this video well like the video i see you in the next one and meantime keep building you

Channel: Tristan Durand Builds

Views: 4,743

Rating: 4.9770117 out of 5

Keywords: Headlight + Kickstand FABRICATION for Cafe Racer Project on Yamaha Virago, front end conversion cafe racer, inverted forks on yamaha virago, yamaha virago xv750 cafe racer, how to adapt headlight on cafe racer, yamaha r6 cafe racer build, cafe racer short kickstand, headlight bracket fabrication, rallye car headlight on motorcycle, cafe racer headlight install, cafe racer fabrication, cafe racer tutorial, yamaha r6 front end on virago, round headlight on yamaha r6, tristan durand

Id: RsVDMc78594

Length: 21min 13sec (1273 seconds)

Published: Wed Dec 09 2020