After a healthy amount of summer travel, I was able to find some time to work on the bike and knock off a few projects.
Frame
After receiving a shop estimate of ~$400 to cut the frame and weld it, I decided I could do it myself. I eyeballed where I wanted the frame cut, put down a few pieces of electrical tape as a mark and had at it. Since I don't have a proper reciprocating saw, I ended up using my drill with a cut off wheel...or 3 of them. Totally turned out to be a crude hack job that needs a little TLC to spruce things up, but it got the job done and the daunting task of shortening the frame is behind me. Yet to put black plugs on the frame to keep water out, but that's easy. Not sure if I need to reinforce the frame further, but I'll ride the bike for a while and see if I notice any flexing or stability issues while cornering.
One of the best parts of cutting the frame off was hammering the hell out of the seat locking mechanism. I started to cut it with a cut off wheel, but it proved to be a tough angle and I was worried about nicking the frame. Out came the hammer and I spent the next 5 minutes getting out my aggression! Finally the entire thing popped off and was sent flying across my garage floor with a satisfying clang. I've still got to de-tab the frame further, but that's for another day and another beer.
Seat
Gone is the Bondo-covered seat and here is the primer-covered seat. I picked up some Rustoleum primer filler and made about 5 passes on the seat, using 400 grit sandpaper between coats. I finally got the seat to where I feel comfortable painting it. Like I've said...this is not the permanent seat so I'll end up painting it myself with some Duplicolor. My friend uses CAD on a daily basis and has access to an industrial-sized 3D printer. Our plan is to take my seat, enter it into CAD, refine the shape (so it's not uneven) and print off the seat using industrial polymer. It will still be very lightweight and should provide more than enough structural support. Since the 3D printer will print the seat pan as a solid piece, I'll be able to remove the wooden chair bottom after v2.
I will post updates and photos of the v2 seat, but for those who interested, I will be able to print out copies of the seat since it's in CAD. If you're interested in purchasing the K75 cafe racer seat, please PM me and we can discuss.
Electronics
Screw holes to secure the taillight into the seat were drilled. Electronics have been hidden below the shell for now. After riding in the rain today, I realize I'll need a little more protection from the elements underneath.
I am fooling around with the idea of rerouting the horn wiring to the storage case below the seat and hooking it up to a garage door remote. Haven't researched this at all, but I would like to be able to trigger the horn and have the garage open. Pipe dreams...
Sadly the rear turn signals just aren't that bright and since they're integrated into the taillight, they are fairly close together. I'd like a little more spacing on them and for them to match the front of the bike. Ordering an additional set of turn signals for the rear to match the front set. Will have to fabricate some kind of holder for them in the back.
Speedometer
Still waiting to sell my old, fully functional speedometer to finance a new one. I'm pretty much decided on the black Acewell speedometer/tachometer. Yes, every BMW cafe racer has one, but I like the look and I can't find anything better. If you've got a suggestion, I'd love to hear it.
Exhaust
No idea what I'm going to do here yet. Thinking of wrapping the headers in black heat wrap and getting a black megaphone exhaust. It needs to be shorter than the stock muffler since the bike is about 15" shorter. Again, suggestions here are welcome.