the point of no return

I finally got tired of looking at my unfinished uninspired project, an XJ 550 bobber with hard struts. Not really digging the rear end or the hard strut mentality, I decided to go for it. Cut the rear off. Now I have to get off my couch and work on it if I ever want to ride again. Took off the swingarm and added 5 inches to it. Replaced swing arm. Cut the whole 3 tube/one tube backbone abhoration that comes from Yami. Plan to extend the single 1.25" backbone further. Then weld 1" tube from backbone to axleplate while swing arm is still in place. A coulple of cross braces and gussets and then cut the swingarm off from the axle plate and remove it. Got some angle finders and levels to use along the way so I go down the road semi straight. I took the bike to a friend's shop to get serious with it. Up until then I had done everything out in my yard since I don't have a shop or garage. Working in the yard with an AD/HD 8 year old boy who wants to help and an equally hyperactive dog that wants to play featch all day is not conducive to good working results. The change of scenery should move the project along quickly. Anyways, here's a couple of pics for progress/regress' sakes.

 

Do you have pix of the swingarm? I want to do the same to my 550.

 

WOW!! That is courageous to cut up your bike like that. I personaly would love to take on similar projects but lack the confidence in my skills and fear that I would never be able to ride the bike afterward.

Looking forward to seeing this project completed. Please keep us posted.

OH and most importantly: good luck with your major project.

 

So I got a little more work done. The weather was bad. Rained most of the day. As luck would have it, about the time the rain stopped, the power went out. Seemed like a good time to stop and head to the local watering hole. I got my backbone extended and top frame rails tied into the axle plate. I got a little more to tie in around the mid section before i can cut the smaller outside sections of the backbone and swingarm. As for the swingarm, sgary, I didn't take pics, but I can. I didn't weld it up to hold up to riding, just to hold the back wheel in place. So , it may not be what you're looking for.

 

Are you going to increase the fork angle?

 

Wizard, I'd like to put a little more rake in it, but don't think I'm going to tackle that one just yet. One day I'd like to put a springer out front. May try to rake it then. From an asthetics stand point, the front tire does need to be kicked out a bit. From a handling/trail type thing, I don't know.
I've seen mathematical formulas and all that jazz on trial. But I HATE math. Just not sure if extending the swingarm without altering rake affected it. So, I guess the big question is, "Do I need to increase the fork angle?"

 

I like the way it looks as-is. It has that tough English bulldog look. Kinda tough and stubby.

 

I like where this build is going! 8)

 

X2...looking good!

 

Just noticed the pegs. Very cool! Where can I find a set?

 

danno, I made those from some double link chain I "acquired"-welded on the bottom. They may not make it through the final build. Was thinking about some forward controls, maybe some round stock with spent shotgun shell casings for cosmetic porpuses. If I decide to go in that direction, I'll let you have first crack at them. Spring loaded, just like factory.

 

Yup, I agree about the solid struts on the rear ( not even good for my back) I went with cutting the shocks instead (much nicer ride for sure)
You have the right idea extending the frame. It should help the ride somewhat with a longer wheelbase. It looks good so far! You'll probably have to go with forward controls anyway, because being you dropped the seat down, you'll be eating your knees when you ride. Forward controls are so much more comfortable anyways and fun to build. That should be one great bobber when your finished. Keep us posted!

 

Hi Bud, how are you going to configure your pipes? you don't have much freeboard there.

 

Got a little more done yesterday. Tied in some more support. Cut some stuff out. I'm really liking the nice straight line from neck to rear axle. I thought 5 inches of stretch may have been too much. But after looking at it now, I think it was the right amount. Painter, you got some pics of your forwards? I'd like to see what you did. Wizard, I really won't know until I do it. I kinda want 2 into 1 on each side with a turn down. Prolly open pipes, so I want them as far back as possible. If I go with forward controls I was thinking about raising them (pipes, not controls) up a little from stock location. Maybe make some nice heat shields out of some 16 oz aluminum bottles. I also have some header wrap that I could wrap the pipes in. I'll just have to wait and see how it starts to take shape once I get started. Things seem to have a way of taking a different direction from what was originally planned. Anyway, I got a couple more pics showing the lines of the bike. Doesn't look like I got much done, but I stayed busy. So, I guess that's a good thing.

 

that thing is going to look sweet only thing i would change if it were me is the flat front tire doesn't go with the bikes lines i would do one with air in it would really complete the bike :lol: keep up the good work

 

I was really getting into the flat tire. Matches the lines on the bike. Besides, it's only flat on bottom.
I"m going to get back on the build hot and heavy this week end. Hope to have some more pics up then. Thanks to all who have left kind words and compliments And I'm always open to suggestion. So let me know what you think could be done different or better.

 

With the stresses that the Trailing Arm will be enduring ... I think thee needs to be "Something" added in-between the Upper Trail and Lower Trail to keep them both reinforced.
A Solid piece "Gusset" with a design cut in it.
Something.
I don't know what I'd do. But, I would do it.

 

Rick, my plan is to put in some bottom rails and cut the swing arm completely out. I'm having trouble getting my hands on a tubing bender. I used a rosebud on a torch rig to get the bends in the top rails. But the bottom rails are going to be too sharp of an angle to heat and bend. I know a guy that has a bender, but our schedules just haven't allowed me to get it yet. In the meantime, I've been fabbing breackets for the seat, fender, tank, etc. I really don't want to start stripping it down until I can get the frame tied in completely. So I'm doing what I can while I can. Yeah, I definitely plan to add more support and a few gussets here and there. Thanks for looking out for me.

 

Just got finished with another day on the bike build. Managed to get the tank mounted. Also got the seat in place and bungs welded. Made a sissy bar out of rebar for the reat fender mount. So I got the tank supports, the seat brackets and mounting for the rear fender finished. The main thing I must get done are the bottom rails. I should have them bent and installed tomorrow. After that I need to build a false oil tank to house the battery and electronics, fab up a headlight and brake light support. And I need to find a way to ge tthe passenger pad on the fender in such a fashion that I can put it on and take it off as needed. Was thinking studs and acorn nuts. Anybody got any better suggestions? Anyways, here's a pic of the bike with tank seat sissy bar and fender mounted. Ilike the way the bottom of the tank matches the lines of the backbone, but it's on one steep angle. No way I can get all the fuel in it as it sits. Was thinking about making the tunnel deeper in the front so it sits a little more level. What do you think?

 

will he still be able to use the center stand one the tire is inflated?

 

I would suggest using Velcro to attach the rear seat pad for temporary use. Just use 4 small pieces in each corner, so they won't be so noticable when the pad is left off. I don't see anybody really wanting to sit on that pad at the angle you have it on now!!
Or like my bobber, I just made a small steel tab that goes under the front pad and bolt thru the fender in the back with an accorn nut. But being your front seat is a spring seat, your going to have to go with Velcro or the suction cup rear seat idea.

 

Bet a pair of Fishtails would go well with the extra length.

 

After trying several times to borrow a pipe bender from a co-worker with no luck due to scheduling conflicts, I took a ride to the local Harbor Freight and bought a pipe bender. Now I can finally start working on the bottom frame rails. I got the desired angle bent into the bottom rails. One of the rails had been fitted up and is ready to weld up. Before I weld, I need to get some plate to extend the axle plate. That should give me some more to weld to for tying in on the axle plate. Should have the frame close to completed this weekend. Here's a pic what the old girl should look like once the bottom rails are tied in. Also have a pic of the seat bungs and front support for rear fender.

 

Very nice, High Five!

 

Today I got the bottom rails and gussetts put in and welded. I also got the swing arm completely out of the equation now. May try to work on the exhaust this weekend and if I have time may try to make a false oil tank to hold battery and electronics. I don't really have a lot left to do with the frame other than a cross brace at the bottom and clean up the mid section. I must admit, when I started this, I really didn't know if I could pull it off or not. I didn't have much money tied up in the bike and figured if I messed it up beyond repair I was only out a few bucks. I'm proud of what I have accomplished so far. If there's anyone out there on the fence about doing something similar to this, I say go for it. I don't consider myself to be that mechanically inclined, so if I can do it, anybody can.

Here's a couple of quick pics. All pics on this post were taken with a cell phone. I hope to get a few pics with a digital camera if I can ever remember to bring it.

 

Tearing a bike in half and building it back up to your standards is tough. It's especially tough if you happen to be a perfectionist. I'm currently on revision 3 on the exhaust. I finally hit on something that may just satisfy me. Should have a good portion of it knocked out and done tomorrow. Hope to have some pics then. Made some forward controls. Didn't like them either, so rev 2 is in the works. The devil is truly in the details, as the finishing touches are killing me. I could have bought a set of forwards and some exhaust, but I want to put my touches on it. And I'm trying to do this on a limited budget...VERY limited. My goal is to be riding it by the first weekend of April. Still got a long ways to go.

I'm thinking of painting the frame gloss black, the tank and fender flat white, and the wheels red. Also gonna wrap the back wheel in wide white wall rubber, thin white walls out front. Maybe red engine paint with the edge of the fins polished out. Anybody think this would be a good look? Does engine paint really hurt the motor?

 

Got my exhaust finally going my way. That was a nightmare. I cut the pipes after the down turn from the head. Took a section out and rewelded to get the pipes high and tight to the frame. First three went great. It's the last one that'll get ya. Every time I'd try to weld the last one, it'd blow hole after hole. Pipe was rusted or just wore thin on the inside. That was attempt #1. Attempt #2 was to try to use some pipes from a cb750. Attempt #2 was doomed from the start. Somebody, somewhere was looking out for me. Whilst driving home from work I spotted a godsend. Some trashy fellow had threw away his old weight bench. Left it onside the road. It was made from round tubing had plenty of bends and looked like a good exhaust size. I took it home and my exhaust (what was left of it) fit perfectly inside the wieght bench tubing. Gave me a little more metal to weld to than a standard butt joint. So, with a little cutting and welding, I now have an almost completed exhaust system, fully custom. Just need to get some chrome turn outs or something, put in another piece of the weight bench here or there, and exhaust is done. And then I can bang my head on some forward controls. Anyways, here's a few pics. One man's trash is another man's treasure.

 

one word : lol

 

Don't downplay your mechanical inclination...the scoot is lookin' AWESOME!

 

I'm really diggin' how it's coming along. I wish I had the skill to pull off something like that.

 

Looks good. Now ith some sanding, and BBQ paint, those will do the trick. Or even some exhaust wrap would cover those welds nicely.

 

Prolly gonna knock the tops of the welds down a little with the grinder, then put a wire wheel on and take it down to the metal. Then I'll shoot some BBQ paint on it. I'll put some header wrap where needed. Still looking for the chrome turnouts. Parts suppliers sure are proud of those things. Contemplating making a heat shield with some kind of decorative something on it. Ain't completely sold on that idea, tho. Don't want to be mistaken for those yahoos in NY. But Budweiser makes these cool looking aluminum bottles that I think would make a nice cover over some 2" tubing split in half lenghtwise for heat shields. Only problem I got is the exhaust on the left is blocking my kickstand. Gonna have to relocate the stand. Got a coulple of pics of what they look like with out prettying them up yet.
Thanks, guys. Thanks for the kind words and encouragement. I'm glad so many of you approve.

 

That exhaust is nice.

 

Ah yes, the old "replace-the-kickstand-mount-idea" is always a hurdle to jump over. It needs to be welded on the frame somewhere, but where?
I suppose it could be mounted on the bottom of the frame, behind the exhaust some where? Just a thought.
I'll have to file that one under "don't make exhaust that gets in the way of the kickstand" category!! What were you thinking?

 

Painter, I was thinking," I've changed everything else, may as well change the kick stand, too". I liked where the pipes ran. Couldn't get 'em too low, cuz the bike is already low enough. I left enough room between the frame and pipes that the kickstand still fits between them. Just can't get the foot in to drop it. Might just modify it in it's original location to work. It's not a major problem. Considering some of the hurdles I've already cleared, it probably wasn't even worth bringing it up. But, I knew if I didn't, someone would have asked about it.
Forward controls are the next hurdle to jump.

 

Your kickstand can still come out from under the pipes. Just make a small rod coming out from underneath the pipes to catch your foot on to pull it out. Make it longer and come out more horizontal than the stock kickstand. That way you can lay the bike over more, and less chance of it getting blown over.

 

Yeah. That's prolly what I'll end up doing. Last thing I want is for it to fall over. That would not be my favorite.

 

On mine, being I lowered it to the point where the kickstand made it stand up too upright, I just took off the kickstand and bent it (heated with a torch) so it layed the bike over more when parked. Now it would take a tornado force wind to blow it over. 8O

 

One word: sweet

 

Been a pretty hectic week with work, so today was the first day I was able to work on the bike. I got the welds on the exhaust ground down and paint stripped off. I sprayed the pipes down with some BBQ paint just like Painter suggested. The pipes turned out better than I expected, so now I don't know if I want to wrap them. Anyways, this is the results. Not too shabby for some junk I found on side of the road.

 

this things hot man, i've been working on the same thing with mine, and i feel so much more motivated

 

Now I'm focusing my attention to the controls of the bike. Thinking of running a jockey shift with the clutch lever on the shift. Kinda made a quickie to see what is what. This isn't in it's final form, just getting an idea.
Painter, I'm probably gonna disapoint you, but if I run a jockey shift, I may be able to lengthen/bend the rear brake foot pedal to a comfortable working location. If that's possible, then I probably won't run forward controls. Here's a pic of my prototype jockey shift/clutch combo.

 

omg, you jsut gave me a great idea for my bike... i have a bud light handle... hmm, this could be interesting

 

im thinking chain link too...

 

Go for it, Schoot.

 

those pipes turned out really nice. kinda makes me wanna do somthn like that

 

bike looks good is there any way i could get a better pic of where you cut the frame

 

Now if only the tap was functional...

 

Tiny, that one isn't. But fortunately, I know where there are plenty of them that are.

 

Spiceymchagis, there isn't just one place where I cut the frame. I"ll try to get some pics.