Prince George Vintage Motorcycle Club
Technical Section => Complete Rebuilds => Topic started by: Dennis on December 10, 2012, 06:32:50 PM
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Since I have two bike builds on the go, and no new donor bike for my flat tracker, I have decided to focus on building my XS650 Bobber to use as my flat tracker. The main advantage is that since this is a ground up build, I only have to put on what I need, rather than take off what I don't. Should save time and shop space.
This is the first mock up with RD400 forks and wheels.
(http://i1219.photobucket.com/albums/dd433/smith5304/002-12.jpg)
Frame jigged before cutting.
(http://i1219.photobucket.com/albums/dd433/smith5304/024-1.jpg)
Frame after cutting.
(http://i1219.photobucket.com/albums/dd433/smith5304/025.jpg)
Axel plates jigged in place.
(http://i1219.photobucket.com/albums/dd433/smith5304/022.jpg)
Jeff's slugs stuffed into the existing frame.
(http://i1219.photobucket.com/albums/dd433/smith5304/039-1.jpg)
First tubing bent and mocked. I have since shortened the front of the tubes so the bend is further forward and they line up perfect with the axel plates.
(http://i1219.photobucket.com/albums/dd433/smith5304/037.jpg)
Peace & Grease, Dennis
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Nice frame slugs - I hardly remember now what I used for mine - but they for sure didn't look like that.
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The hardtail is now welded up. I am pretty happy with it. Still needs some grinding and I will probably add some re-enforcement to the lower frame rails.
(http://i1219.photobucket.com/albums/dd433/smith5304/040-1.jpg)
The tank is borrowed from my drag bike. Its originally from a YZ80. It does not fit as perfect as I hoped. Nothing an angle grinder and MIG can't "adjust." The seat is borrowed from my Ironhead Sportster. Geez .... if I keep borrowing parts from my furloughed bikes I should call this one the "Wedding Day Bobber."
(http://i1219.photobucket.com/albums/dd433/smith5304/041-1.jpg)
Got the RD400 wheels blasted. I have Jeff working on making offset sprockets. After that I'll get his help converting the rear to take a 20mm axle up from 17mm.
(http://i1219.photobucket.com/albums/dd433/smith5304/042-1.jpg)
Peace & Grease, Dennis.
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New bearings were a cake walk. 5 minutes at Kaman. About $28.
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Bent Forks. Have a real close look at the first photo above and tell me if you can see any bends. I can now, but I had no idea until Brandan pointed it out on Saturday night at my garage.
The tubes are not pitted, and they are not so badly bent that I never noticed it before. I have read several articles on tube straightening. I need access to a fairly huge press, a heavy 34mm i.d. ring (goes around the tube at the spot where the tube gets pressed, two centering (vee cut) blocks, and a dial indicater. I don't have any of this stuff.
Query: anyone equipped to assist?
I may just see if Jeff or my nephews can do it, but I'd like to do it myself as a learning experience. Hmm, maybe an excuse to buy a press...
Peace & Grease, Dennis
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Jeff has in fact straightened forks before and would be more than willing to assist you. Maybe on Russ' press- his shop has heat. Gonna tear into your 'Zuki carbs tonight. CHEERS.
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The lathe is nice to check and re-check your work as you go - but a pair of v-blocks work just as well, if a little more slowly - and the bending part of straightening stanchions is not difficult with a little force amplifier. I have been straightening them in my pipe bender for some time now. I cut pipe sections as shims to get a nice fit in the pipe-sized shoes - the same tools and technique as for bending handlebar tubing. It's not complicated, but like everything, more time spent equals better results. The forks on the red Guzzi were bent up pretty good after spitting off my sliders and front mag - but they are fine again after about an hour and a half of messing with them, though one of the sliders split at the top as it was leaving the scene, and Jeff will have to weld that up and machine it round for me again before I can reassemble the front end... so I can get on with trying to straighten the bent frame.
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The lathe is nice to check and re-check your work as you go - but a pair of v-blocks work just as well, if a little more slowly - and the bending part of straightening stanchions is not difficult with a little force amplifier. I have been straightening them in my pipe bender for some time now. I cut pipe sections as shims to get a nice fit in the pipe-sized shoes - the same tools and technique as for bending handlebar tubing. It's not complicated, but like everything, more time spent equals better results. The forks on the red Guzzi were bent up pretty good after spitting off my sliders and front mag - but they are fine again after about an hour and a half of messing with them, though one of the sliders split at the top as it was leaving the scene, and Jeff will have to weld that up and machine it round for me again before I can reassemble the front end... so I can get on with trying to straighten the bent frame.
I was talking to Bulldog and he suggested the lathe method for the final tweaking.
An excuse for a press is a lower threshold than an excuse for a big lathe. Then again, I'd love to have a lathe.
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For a somewhat reasonable lathe, check out Grizzley Industrial in Bellingham. They have a web site as well an awesome "free" cataloge.
http://www.grizzly.com/
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No photos but an update. I made a cool tool for bumping out a dent in the tank. I was so proud of myself that I had to show Russel. I also wanted to show him my bent fork tubes. Rather than explain how to straighten them, he just pulled out the tools and away we went. Both are within 5 thou of perfect.
Fork lower legs have been stripped of clear coat and wet sanded to 400 grit. Next will be 800, 1500 and 2000.
Jeff made my offset sprockets. I now have three sizes to work with. He currently has my rear wheel and is making the internal spacer that goes between the bearings.
I have the front rim spokes masked off for painting.
Peace & Grease, Dennis
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Forgot to take photos tonight. My little Beezer is finally running like a hot dam all the bugs are gone. Nice hot cam, ported, long intake manifold and a few other goodies. I am going to run 400 rear and 350 front.
British Bulldog
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Starting BSA 500 single for me and a triumph 650 TR6 twin for Brendan. They both are Flat Trackers. Also on the go now 1960 Norton ES2 500 Single, 1969 BSA 500 Royal Star, 1952 BSA 125 Bantam and 1964 BSA B40 Enduro Star lots of fun. The Brits are going to do it again.
British Bulldog
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This is with an engine in and the little Yamaha tank for looks.
(http://i1219.photobucket.com/albums/dd433/smith5304/007-4.jpg)
I have a weekend mostly free, so I plan to get some work done. I want to try to pry out a few more dents from the tank, and then committ to Bondo. I have ordered the Caswell tank liner for this one. I've used Kreem, POR 15 and now I want to try this stuff. Good reviews.
I want fabricate exhaust and peg mounts before I pull the engine again. Then the frame and triple trees will go off to Jeff's again for modification. The stem from and XS650 triple tree needs to be swapped into the RD400 triple tree.
Peace & Grease
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I just got back from HUB Insurance Brokers. I worked with Nadine this time. I am now the registered owner of a 1972 XS2. I don't need registration for flat tracking season, but this will be one cool little street bobber after that.
(http://i1219.photobucket.com/albums/dd433/smith5304/bwvintageflattracking_zps4906e38d.png)
Peace & Grease, Dennis
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Most of what I have been doing would not have made for good phtotos... so there has been a hiatus. Recent work is more photogenic.
The wheels were sand blasted, carefully masked, and painted with cheap semi gloss black paint.
(http://i1219.photobucket.com/albums/dd433/smith5304/052_zps7e31c12b.jpg)
Jeff elongated the stem in the triple tree. The forks are from an RD400. To fit, the stem had to be lengthened. I gave Jeff the old triple trees, and a set of bearings and races from an XS650 with instuctions "make 'em fit". The first picture should show the weld and fabrication, and the second show both parts together.
(http://i1219.photobucket.com/albums/dd433/smith5304/054_zpsbb0674e1.jpg)
(http://i1219.photobucket.com/albums/dd433/smith5304/053_zpsd57270de.jpg)
For those following the theme behind this build, I plan to race it only one season and then make it street legal. One of the things | have observed is that hardtailed flat trackers almost always have a pillion pad mounted so that the top was flat, like an extension of the rider's seat. In choppers, the pillion pad is always mounted on an angle, pushing the young lovely babe which has just accepted a ride, crotch first into leather jacket and vibritory netherlands. I still build bikes like I was 20 and single, not 52 and married. Single guys bikes are just way cooler. My wife thinks so too.
(http://i1219.photobucket.com/albums/dd433/smith5304/056_zps4658dcd8.jpg)
A more traditional look is this, but I kinda think its lame.
(http://i1219.photobucket.com/albums/dd433/smith5304/058_zpsac68c30c.jpg)
(http://i1219.photobucket.com/albums/dd433/smith5304/057_zpsb9619d91.jpg)
I spent most of Sunday making the gas tank mount. I won't weld it on until near the end when I finaly committ to where the gas tank will live, but this picture should show the mount and how it is supposed to ultimately work.
(http://i1219.photobucket.com/albums/dd433/smith5304/059_zps5d36f41c.jpg)
Peace & Grease, Dennis
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Looks awesome Dennis keep up the good work. I can't wait to run my BEEZER against her win or loose it will be a blast and a bucket of fun then some. We will have the beer nice and cold and lots of it. Do you know how many others are been born?
British Bulldog
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I finally got around to taking some new photos.
The forks are straight with fresh seals. The wheels have new bearings, seals, paint and rubber. The gas tank and seat are mounted. The rear fender brace had to be cut and narrowed. I still have to do the front mount for the fender, mounts for the battery and voltage regulator, and finish the foot peg mounts and brackets. I was hoping to get all of that done last weekend but it didn't happen.
(http://i1219.photobucket.com/albums/dd433/smith5304/004-7_zpscbacc4fa.jpg) (http://s1219.photobucket.com/user/smith5304/media/004-7_zpscbacc4fa.jpg.html)
(http://i1219.photobucket.com/albums/dd433/smith5304/005-7_zps871d2584.jpg) (http://s1219.photobucket.com/user/smith5304/media/005-7_zps871d2584.jpg.html)
Jeff made these rear axle spacers from a marine propeller shaft. They're stainless steel.
(http://i1219.photobucket.com/albums/dd433/smith5304/006-6_zpsa6f03cdc.jpg) (http://s1219.photobucket.com/user/smith5304/media/006-6_zpsa6f03cdc.jpg.html)
Peace & Grease, Dennis
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I will try to post some new photos soon. The fab work is completed. Time constraints, and the fear of dumping the bike while racing have forced the choice to simply use the same cheapo rattle can paint (yellow) for the rear fender. I am going to borrow the little tank from my drag bike, because the one I was planning on using needs too much work. I would hate to spend a bunch of money on a liner and paint job, only to ding it all up when I crash.
It will be a roller for the Motorcycle Awareness Show 'n Shine, but I likely won't have it wired by then.
Peace & Grease, Dennis
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Saw a guy today riding a 650 rigid with an over length springer and rake wearing a green metal flake helmet. Looked cool. CHEERS.
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Dennis it sounds good. Keep up the good work can't wait to see that Flat Tracker of yours. Fast 1 it might be Fuddy, Dennis's nephew's friend. I saw the bike a couple of months ago, it looks like somebody did a pretty good job on it, if i remember right. The Yamaha 650 XS is a great engine though, from what i have seen and been told over the years. I never owned one though.
British Bulldog
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On the weekend, I guilted the Chopper Boyz into helping me with some fab work. Emery made the battery box. His own design and it works great. Note that there is no writing left on the battery. He removed it "'cause its cooler."
(http://i1219.photobucket.com/albums/dd433/smith5304/002-14_zps8a808b1b.jpg) (http://s1219.photobucket.com/user/smith5304/media/002-14_zps8a808b1b.jpg.html)
Rear fender spray bombed to match the drag bike's gas tank. I will have to compare the hue later. Same paint, but the gas tank has had a year to fade. No Bondo and just a smidge of primer so it kinda sucks. Good enough for racing. One day this bike will be a chick magnet and for that it will be all smooth and shiny.
(http://i1219.photobucket.com/albums/dd433/smith5304/009-2_zps10aa8f4b.jpg) (http://s1219.photobucket.com/user/smith5304/media/009-2_zps10aa8f4b.jpg.html)
I am closely monitoring the weather this afternoon. If the sun comes out I will head home early and paint the frame.
Peace & Grease, Dennis
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Frame done. Everything done but washing the engine and polishing some aluminum. Assembly is scheduled for Sunday (barring yard work or other familial duties).
(http://i1219.photobucket.com/albums/dd433/smith5304/001-10_zps107e9314.jpg) (http://s1219.photobucket.com/user/smith5304/media/001-10_zps107e9314.jpg.html)
Peace & Grease, Dennis
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The Wedding Day Bobber is now ready for the Motorcycle Awareness Show. It is not finished but will have to do. I screwed up on the foot pegs. I have made two sets and neither turned out right. I made assumptions about exhaust clearance which were wrong. The wiring needs to be completed and few other small bits. I will have to start all over with the foot pegs though.
(http://i1219.photobucket.com/albums/dd433/smith5304/006-6_zps9e1633b6.jpg) (http://s1219.photobucket.com/user/smith5304/media/006-6_zps9e1633b6.jpg.html)
(http://i1219.photobucket.com/albums/dd433/smith5304/005-7_zpsd00a7761.jpg) (http://s1219.photobucket.com/user/smith5304/media/005-7_zpsd00a7761.jpg.html)
(http://i1219.photobucket.com/albums/dd433/smith5304/004-7_zps6a451c4c.jpg) (http://s1219.photobucket.com/user/smith5304/media/004-7_zps6a451c4c.jpg.html)
(http://i1219.photobucket.com/albums/dd433/smith5304/003-11_zpsd0afbc8e.jpg) (http://s1219.photobucket.com/user/smith5304/media/003-11_zpsd0afbc8e.jpg.html)
Peace & Grease, Dennis
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Thought I should finish this thread with a picture of the bike at O'Keefe's.
(http://i1219.photobucket.com/albums/dd433/smith5304/Okeefe1_zps32250d54.jpg) (http://s1219.photobucket.com/user/smith5304/media/Okeefe1_zps32250d54.jpg.html)
Although the plan was to turn it into a street legal bobber, my current plan is to leave it as is and race it again next year. I am starting a new thread on the Smithers xs650 bobber.
Peace & Grease, Dennis