The peg mount will be mounted something like this - however it is necessary to build another plate and mount it farther out to get the proper width and make room to mount the brake pedal.

I am wondering if it would be possible to make some round extensions that bolt onto the inner plate and then to the peg mounts......rather than building a second mounting plate?

After spending a bit more time looking at this......the way Ohiomoto did it with an inner and outer plate is likely the best way.  It provides a way to mount the brake pivot, and also a gear shift pivot if it turns out I need one.

I believe there is not a lot of room to move the pegs around....or at least not with using the XS400 pegs as donors.  I am trying to keep the pegs inward and as low as possible - the brake pedal pivot and exhaust header limit how far down you can go.

I have sat on my Cafe' and held my feet where I believe the pegs will end up, and it seems like a good location.  The full bench seat will likely be an inch or two higher than the solo Cafe' seat - and that will help as well.

If you look at the photo of my Cafe' bike rearsets on Page 1 of this thread, and then the footpegs on the Suzuki Tempter - you can see that Suzuki kept the pegs pretty far back when they made the Tempter - but they are about the same height as these will end up.  I believe I will be a few inches farther forward than the Tempter pegs.  

I had to separate the brake shaft from the brake lever....I likely will fabricate my own lever to better fit the shape of the swing arm.

I put the shaft in my lathe and cut the weld down to be level with the arm.

I put it in my press - and it took quite a push to get the remaining weld to pop loose!

Next I had to machine out the ID of the bushing so the shaft would fit inside.

This is the first time I have ever done an interior bore like this, and it worked well!

I am gaining so much respect for people that do this kind of work with basic tools like hand drills, hacksaws and grinders!  I used to work like that - but I have watched for good used tools at affordable prices and I am pretty well stocked up with some fancy tools - and I am learning how to use them.  It is hard for me to stay good at welding however - I can go years between welding projects and I lose the skills for nice pretty welds!  

After dinner I was able to cut the rough blank to the final shape.  The square with the "X" inside is where the 1" tubing will weld to the plate and attach to the inner mounting plate.

I have found that making a pattern on old file folder paper - then using spray adhesive to stick the pattern to the steel helps me see where to cut much easier than trying to follow a pencil mark or scratch on the steel.  My eyes are not seeing as well as they did when I was younger!

The bandsaw leaves a pretty rough edge, and the metal has a bit of rust and mill scale on the surface - so it needs some cleaning up.

Dave,
I enjoy reading this thread. Your cafe is a beauty of the kind that makes me think it could well have rolled off an assembly line, and I mean that in the best sense. I feel torn between bobber or cafe. I think cafe will win. Making pretty welds, I have the same problem. It takes not just talent but most immportant every day practice to make those stacked dime welds. I can't do it either, to my utmost frustration.  Argon costs around 70$ per hour, so the cost of practicing is not neglegtible either.