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Brian Bongfeldts's RD400 Project

Brian's RD400 Project Cafe Racer Before Right Side

Here is a series of pictures that recorded the making of Brian's custom RD400 It started out as a used RD 400. Cool Bike as is, but not cool enough for Brian. It was completely stripped down to the bare bones and sand blasted. All the unessesary brackets and holders were removed from the frame.

Brian's RD400 Project Cafe Racer Before Back Right Brian's RD400 Project Cafe Racer Virgin Frame
Brian's RD400 Project Cafe Racer Rear Welding

The rear of the frame was cut off and a loop was added that would be the TT style rear of the seat.

Brian's RD400 Project Cafe Racer Cafe Seat Welding
Brian's RD400 Project Cafe Racer Cafe Seat tail Welding

The rear of the frame was cut off and a loop was added that would be the TT style rear of the seat.

Brian's RD400 Project Cafe Racer Welding side shot

Another loop was added where the rear of the tank will sit to fill in the gap and make the seat pan look more custom.

Brian's RD400 Project Cafe Racer Finished Seat WeldingBrian's RD400 Project Cafe Racer Finished Seat Welding 2 Brian's RD400 Project Cafe Racer Finished Seat Welding 3

Another loop was added where the rear of the tank will sit to fill in the gap and make the seat pan look more custom. Next the seat and caps were filled in with hand formed sheet steel and welded. The seat area is now finished and awaiting final finish grinding and smoothing. Below is the general finished fab work for the seat and tail.

Brian's RD400 Project Cafe Racer Finished Seat With TankBrian's RD400 Project Cafe Racer Finished Seat With Tank 2
Brian's RD400 Project Cafe Racer Rear Master Cylinder Outside

Next a rear master cylinder was added. A FZ750 unit was used and new tabs were welded to the frame.

Brian's RD400 Project Cafe Racer Rear Master Cylinder Inside
Brian's RD400 Project Cafe Racer Rear Sets

Next a rear master cylinder was added. A FZ750 unit was used and new tabs were welded to the frame.

Brian's RD400 Project Cafe Racer Rear Sets 2
Brian's RD400 Project Cafe Racer Powder coated frame

The First Finish

The front end was added and some cool clubman style handlebars. The stock RD front end was used and the lower legs powder coated the same color as the frame.

Brian's RD400 Project Cafe Racer Powder coated frame with forks
Brian's RD400 Project Cafe Racer rolling chassis RZ350 wheels

The bike was finally ready to make a rolling chassis. A set of RZ350 wheels were fitted to the bike and all looked like it was well under way, 

Brian's RD400 Project Cafe Racer rolling chassis RZ350 wheels 2
Brian's RD400 Project Cafe Racer rolling chassis RD400 Rear Wheel

BUT.....The rear wheel inevitably was not going to work out. Brian tried hard, but without making some serious changes to the existing structure, it was a lost cause. Reluctantly Brian added powder coat to the original RD400 wheel and it actually worked out well. It actually ended up looking good. He did not want to use the RD front because he had already planned for a R1 Yamaha front brake system that was a MUST for the project to be as he wished. The rear wheel ended being a small sacrifice. As you can see in the pic a set of Emgo shocks was added and the look was coming alive!!!

Brian's RD400 Project Cafe Racer rolling chassis RZ350 wheels 3Brian's RD400 Project Cafe Racer with motor installed
Brian's RD400 Project Cafe Racer with motor installed 2

The bike was finally ready to make a rolling chassis. A set of RZ350 wheels were fitted to the bike and all looked like it was well under way. Here are some close-ups of the R1 front brake system. A adapter bracket was fabricated to make the system work and the disk was a direct match for the RZ wheel.

Brian's RD400 Project Cafe Racer R1 front brakes Brian's RD400 Project Cafe Racer getting there Brian's RD400 Project Cafe Racer R1 front brakes 2
Brian's RD400 Project Cafe Racer Piston Headlight 1

Another cool mod was this one off custom made piston headlight. All hand made by Brian. How cool is that!?

Brian's RD400 Project Cafe Racer Piston Headlight 2
Brian's RD400 Project Cafe Racer Working Electrical

And Then There Was Light...

A custom wiring system was installed and tested and finally the bike was ready for its final touches. Finished pictures below.

Brian's RD400 Project Cafe Racer Finished Right Side
Brian's RD400 Project Cafe Racer Finished Rear Right Side Brian's RD400 Project Cafe Racer Finished Right Side 2 Brian's RD400 Project Cafe Racer Finished Rear Brian's RD400 Project Cafe Racer Finished Right Front

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