Floors refinished!

Well...refinished my floors...that was a lot of work.  I used espresso colored stain and then two coats of clear satin polyurethane.   I also sanded the whole thing before staining.  Turned out great!
-Jacob

Skull bottle engravings

I made a set of three skull engravings on some green bottles.   First time I used the new flex bit on the dremel.   Worked great and I was able to spend more time carving without breaking my wrist.
- Jacob

Customized Glass Bottles

Being the experienced drinker of fine bourbons and wines that I am...there never seems to be a lack of empty glass bottles around.   So instead of just tossing these beautiful objects in the trash I've started to save them for a new project.

I was lucky to receive a new Dremel tool as a gift.  Pretty much the coolest thing ever.  As I experimented with the different bits that I got with it I discovered how fun it is to carve and etch glass...

So a new hobby is born...as though I need another hobby.

This is one of my first bottles.  I like how it turned out.  Stay tuned...more to come!

-Jacob

Bocaj Industries - More Than Motorcycles!

Until now this blog has been mainly for cataloging the progress on my motorcycle build.  Well, it will continue to do that, but in addition, I will be adding some new content from time to time.  Basically whatever other creative projects I may be working on that I think are cool and would like to share.

So, on that note...

Pan Target-
Have you ever wondered what to do with all those old, useless, worn out pots and pans?  Shoot them!
I welded up a nice little frame out of some thin wall tube steel I had from an old carport.    The two cross bars are detachable with pins so you can take it apart for transport or storage.  The targets are just some old pans that have ruined their last egg.  Added a little paint so you can see where you hit.  When the pans are worn out I'm sure I'll have some more to add to the cause.

-Jacob

Bocaj Industries - 1971 Honda CL350

A couple of improvements to mention today.  Being the dead of winter here in good old Wisconsin, I haven't gotten much opportunity to get out in the garage and weld.  So the seat sits, still mocked up in cardboard waiting to realize it's full potential as a shiny metal creation.  Oddly enough, I did find enough time to stare at this thing for a while only to realize I don't care much for the line of the front end.  The gauges and headlight bucket are too high as well as the handlebars...So, I decided to tear it all down and try a new approach.  I'll be running new headlight ears moved lower on the trees and will fabricate a new bracket for the tachometer and speedometer to lower them as well.  I've also decided to run clip-on handlebars to lower the stance of the bars while bringing up the angle of the grips for a more comfortable ride compared to the one piece clubman bars I had on before.   The idea is to make the gas cap the highest part of the line of the bike.  In the process of making these changes I've refinished the headlight bucket to match the bare metal tank and polished the hell out of the triple tree.

-Bocaj

Bocaj Industries - 1971 Honda CL350 Cafe Racer

Now that the electrical is well on its way to being done, I have the opportunity to focus on the seat for a while.  The first step for me for creating a new seat pan is to have a nice flat surface to work off of.  So, this brings up the first issue...the battery.  As it sits in it's factory location, it sticks up about an inch and a half above the frame.  This is no good if you want your seat pan to sit flat on the frame.  So, I made two small brackets and modified the battery box to attach to these brackets.  After reinstalling the battery box with it's new mounting points it now sits about half an inch below the frame. 

Next, I was able to get some sheet metal and lay it flat on the frame to get a rough sketch of the shape I needed to cut out.  I got the metal cut to a nice shape I liked and then carefully rolled the edges for a nice finished look.  Finally I added the little kick-up on the tail of the seat.  Fits great!

I had been on the fence about the design of this seat for a while as to weather or not it should have some kind of cowl on the back or if it should just be flat.  After some heavy duty staring I decided to mock up a cowl with some cereal boxes which work awesome for sheet metal mock up by the way.  I fell in love with the result.  Now I have a nice template to use to cut out the cowl section from sheet metal.  I'll tig weld it all together when I have all the pieces cut out and ready to go.  One last little touch to complete the look and line of the bike is I raised the back of the tank about 1.5 inches so the line on the bottom of the tank now flows nicely into the new seat.  I'll need to make a bracket to keep the tank in this new position.  I also still need to work on the front section of the seat to create a small curved cowl to fit over the gas tank mounting brackets.  So, a little more work to do on the mock-up stage of the seat and then some fun welding in my future. 

-Bocaj

LIGHTS!  Played with some battery acid and got that bad boy all charged up and installed.  Got the new LED turn signals and tail light all wired up as well as the new headlight.  I also got a new rear brake light indicator switch that connects to the rear brake foot pedal.  The old one was not working.   Nice and bright and fun to see some "life" in this motorcycle!  The turn signals do not flash right now because they are LED bulbs and don't pull enough of a load to trigger the stock flasher relay, so I need to get a new electronic flasher relay to replace the stock one and we'll be in business.  The speedometer and tachometer light up nice as well.  Also working well is the starter!  I can't wait to get some gas lines run and fire this thing up...Work on the new seat is well underway.  Stay tuned.
-Bocaj

I love getting new parts in the mail!  The new sprocket keeper and bolts showed up yesterday and I found some time to install it right away along with cleaning up the area under the sprocket cover.  With the sprocket securely attached and my clutch adjustment put back together I could mount the drive chain and put the sprocket cover back on the engine.  The foot control shifter can now go back on too.  
-Bocaj

Huh...that's weird.  So, as I progress on this build, the corners I cut are very vibrantly shown to me.  This time it was when trying to put the chain back on the sprockets to run the rear wheel.  As I was fishing the chain up and over the sprocket that comes out of the engine right next to the clutch connection, it was feeling very loose.  Then...off it came, right into my hand.  What the s*$t is this!  So, I had to take this small cover off to be able to see what was going on behind it in this mysterious Bermuda Triangle where parts just fall off in your hands...  Sure enough, that means taking the exhaust off and the foot controls off as well.  When I finally got the cover off I found more mud wasp nests and a wad of crap the size of my fist.  But more interesting is what I did not find...no keeper plate or bolts for the sprocket.  So, I ordered a new one that should arrive shortly.  Goes to show ya, the one place you don't look on your build is where your problems will be hiding...be thorough and take your time.  The end result will benefit.
-Bocaj

As sometimes happens while being creative, I've changed my mind.  After doing some serious sitting and staring, something just wasn't looking right to me.  So, out comes the grinder.  I removed the chopped rear fender and the new taillight and cut off the rear seat bracket making a nice flat surface to mount a new seat pan.  I also removed the old seat swivel mounts and got rid of the old seat pan which I had been planning on recovering.  So, next I needed to create a new seat pan...This cardboard cut out is the first draft and will eventually be transferred to a sheet of metal and mounted to the frame.  A nice thin pad of some type will complete the look.  After sitting on it with the new seat design I can feel quite an improvement in the comfort of the hand controls.  Just lowering the seating angle a couple inches really helps the comfort of the whole design.  The idea is to get a side mount tail light with a license plate bracket for the right side of the bike and leave the seat nice and simple and clean.  I'm liking this new direction and am glad I made the jump into some more fabrication with it...when sparks are flying you know you're having fun!
I also got both of the carbs rebuilt and installed with their new filters...oooh shiny! 
-Bocaj

I finally got the front tire and wheel all fixed up and clean.  I put a new tube in it as well.  The brake pads are still in good shape so I kept them.  Now it looks almost done...because it is.  Next I have the carbs to rebuild and then fuel to run.  I just got my new petcock in the mail.  After that, some wiring and it should fire up.  The last thing is the seat.  Things are getting down to the nitty-gritty.       

-Bocaj

I've completed the back end by chopping the rear fender by 5 inches on both sides, adding new directional lights and a new tail light. I like the results. I've also popped the rear wheel back on which was necessary to see the whole picture. Lots of balancing with that thing...Front wheel is next, then electrical and finally fuel. Stay tuned...
-Bocaj

I have successfully reassembled the switches and have them nicely fitted back on the new handlebars. Gave the levers a face lift and slapped those on too. New grips and mirrors to finish it all off. Next order of business was to attack this nasty rear wheel. Lots of loose spokes and rust. It ended up looking like new after a couple hours of cleaning. New brake pads and springs and it's all set to be installed. Once the wheel is back on I can start to fit my rear fender and rear lights.

-Bocaj

I got my new headlight bucket and threw a coat of paint on it. Added a flat black racing stripe down the center for a little accent. Also got the wire harness fished through the hole in the bottom of the new bucket. Its all snugged up and in place so I threw the new H4 style headlight assembly in to see how it is looking. As well as the new turn signals and the new clubman handlebars that fit well and look nice. Next task is putting the switches back together that I took apart to get the wires out of the old handlebars... Springs and ball bearings all over the place!.. Also need to get the new grips and mirrors on the handlebars. After that I can wire everything up and test it all out. Looking like a motorcycle...

-Bocaj

The weather finally warmed up which means I can get back into the garage. After 24 inches of snow and a good two weeks of sub zero temperatures, it was hard to imagine how great a 40 degree day feels. So, I made the best of it. I got the front end all cleaned up and put back together. It is back at home on the frame. Looking good so far.

-Bocaj