My attempt at a rigid bobber XJ

Does Your snap-on guy sell KY? In my opinion they all should. its highway robbery.. haha.

 

No worries on the thread jacking haha. I'm curious too.

Got my tail lights in today.


Spent WAY more time than I thought fabbing the seat mounts.



The ban saw took a dump so I'm having my dad fab up the plate mount and key switch mount out of some templates that I have to drop off in the morning. I'm also having a friend of mine take my sissy bar measurments to work with him and we'll get that bent up. Getting closer!!!!

 

Well I got my license plate mount done, sissy bar is almost done, and the key mount (forgot to take a pic) is done. The key now resides under the seat facing the r/h side of the bike.




Sissy bar has a date with the torch and press at a friends work tomorrow and then I think the fab work is complete once I fill the fender holes, mount the tabs on the sissy bar, and fill the sides of the tank with a few small details to go.

 

bikes looking great just got started stripping my wiring harness not much fun i wanna pull my hair out almost done soon paint cant wait to see this thing done

 

I start tear down tomorrow and grinding, I'm not looking forward to it.

Well here's where my key switch now resides.


Here's the rough in part, all the fab is done. Now I have some body work and chassis grinding to do, like all my welds and some brackets etc... I'm liking the small headlight I ordered in.

 

where can one acquire that small headlight? Fleabay? link please?

 

Yeah it was Demon Cycle's store on ebay.

 

Bike looks great man. I am just starting the strip down on my 82 XJ650 J and stoked. If you dont mind me askin what did you use for pods and did you have to rejet? Did you have a wireing diagram?

This is the first bike I have ever chopped so I am sure I am in for a few head aches but if you have any tips on the welding (do's and Dont's) or any good advice I would love to hear it.

Love what all you guys are doin to these beasts (You, Crath, Eflat, ect)
Keep it comin.

Bugz

 

Bugeater - This was my first bike chop too. I have not had the bike running yet with the pods. As far as they go I just got the 52mm pods off of Ebay. I've seen stock jetting and one size up suggested. We'll see how it runs with stock jets and I'll go from there. As far as tips for welding, just good clean surfaces, measure twice, cut once, and make sure it's where you want after you tack it in place.

I got the bike torn down ready for grinding and paint. Can't wait to get this thing on the road! The weather is starting to get nice.

 

Just tuned my carbs up to snuff (thanx to Wiz) and got everything running pretty. So now its time to start stripping and getting ready to chop. I figured I would get her running nice and smooth before I ripped her apart!!

Have you started the rewire on it yet? I have seen a few wireing diagrams but that s@#t is a different language to me!!

Looks great though man I can't wait to see it all come together. Its gonna be a Beaut.

Bugz

 

I'm not going to "re-wire" the bike, but eliminate what I'm not using. I pulled the factory harness out and before I route it back in I'm going to cut out the majority of what I don't need and then fit and cut the rest with no engine/tins on the bike. I found this link that I'll be using for reference.

http://www.xjbikes.com/Forums/viewtopic ... art=0.html

 

heres the diagram that i just used

http://www.currentobservations.us/image ... Series.jpg

 

P2 - Same diagram I had the link to, but thanks for the direct link to it!

I didn't get a whole lot done last night other than get all the extra tabs/brackets taken off the frame. It's ready for bondo/sanding/paint. I should have the wheels/tires done and back over with the bike when I start on the frame again.

 

Yeah I have seen that diagram around its a good one. Thanx for the links.
Only problem is im up in Canada and they dont let us do anything cool to our bikes!!
I have to have break lights, turn signals, a light for my licence plate, a speedo, I can't remove the fenders and I cant have strait pipes.......... Im gonna cut it all off anyways!!!!

Pretty soon there gonna make us ware seat belts!!!!
I am gonna try to do all the lights and the speedo but Ill be damned if Im not choppin the s@#t out that bike!!

 

Hey Q/H I have heard there can be a few problems with the swing arm or somthing making contact when welding the frame. Did you find you had to do anything special with the weld?

 

I did grind material away at the top of the flange to clearance it for the bolts that hold the u joint to the trans due to the angle. I didn't weld any material at the pivot of the swingarm.

 

Got the frame painted but am not happy with it. I was having some reaction issues with the paint and I'm out of time to worry about it before I move. If I keep the bike over the winter I already have changes that I want to make and I'll take care of it then. Got the diff done with filling the "Yamaha" logo and getting it painted. The sissy bar in the pic is painted as well as the lower fork triple not in the pic painted. I have to do the fork lowers and upper tripple and assembly starts tomorrow.



Can't wait! I hope to be rolling next week with it.

 

Lots of little things kept slowing me down but I got to a decent stopping point. I keep forgetting about all the little things I hadn't painted. Tomorrow it should have the motor in and I hope quite a bit more.

 

bikes looking great i just droped mine off at the paint shop

-tony

 

Tony I wish I could have went that route. This is being done on the CHEAP. I think I'll be around 1200 total spend including the bike.

 

Getting closer, still hope to have most of it done by the weekend and just work on the tins and finish wiring next week to fire!

 

lovely! how do the drag bars without risers clear the maxim tank, or do they hit?

 

She's Look'n Bitch'n! Can't wait to see her done!

 

my buddy has a paint booth at his house he owed me a favor thats why its getting done there or i would be painting it myself too.the bike looks sick all together/ i rode mine before paint and its a blast it handles so well and feels better than it ever did with shocks

 

You're gonna wish you did.

 

I don't see why when if it were to try to pivot it's being transfered all the way up through the frame. It can't move or brake a weld. Even if it could "break a weld" the metal would tear before a weld should break if welded properly.

 

ok.

 

Thanks for your input....

 

I did my frame the same way and put it through hell as long as you weld the shit outta it you should be fine, on the other hand I did always kick myself for not putting on any bottem rails

 

Solid beads with good heat/penetration, I'm not worried at all.

 

i agree i didnt weld my swingarm in place either havent seen any problems yet but a good weld should hold up fin the tubing i used was twice the thickness of the stock frame

 

I used .120 DOM for the new frame as well.

Well I got the harness thinned out tonight and lay'd it on the bike to see if it'd turn over/spark, and she did. If I get the bike rolling before the end of the week she won't have the paint/body work done, but I move on Friday so I'll hussle!

 

how did you mount the headlight to the bike? Im trying to figure out if i should buy the same headlight or get those ugly clamp/bracket style headlights...

 

I cut some box stock in half so it was like a small piece of angle iron and bolted it to where the brake junction block used to bolt. I ditched that and went with a single stainless brake line I got from Pegasus racing.

Tonight I got the harness taped up and put IN the bike instead of on top. I'll finish that up tomorrow, get a regular style petcoc for the gas tank, and maybe fire it up!

 

Worked on the bike tonight but my phone died so I couldn't get a final pic after tonight.

Where I started


Half way through after getting tail lights


I got the tails, brake, and turn signals working and got the wiring routed. It was fun running brake and turn signals on the same filiment but got it sorted out with a 12v diode.

Body work tomorrow and primer hopefully before or on friday so I can get it home friday night in the new garage!

 

I HATE body work. Hopefully done with it tomorrow night and ready for primer etc.

 

I didnt weld mine either and have put over 1000 miles on it this year. No problems yet.

 

I think I'm done with the body work finally. Tomrrow is prime, sand, prime, sand and then ready for paint. This part sucks, I'll take wiring over this crap any day.

 

Quarter horse, you must have some serious time on your hands, that bike is sweet. I was wondering what you used to paint the wheels, and what tools you used to prep them? I want to paint mine all black but I am wary after a couple painting nightmares recently.

 

Time I don't have, what I do have is a nack for working on a little bit of sleep and a VERY understanding wife that has been taking care of our 16 month old son by herself most of the time and I owe her big.

To prep the wheels clean them with brake clean, then use a Preps-all cleaner/wax remover, scuff with scotch brite, self etching primer, then paint. It was a pain in the butt and I have a few fish eyes in 'em but you obviously can't tell in the pic or from 10 feet away.

I finally got it done and home!

Man talk about a bucket of nerves and excitment on the way from Jason's garage to my new house. I'm so stoked to get it home I'm giddy just typing this. There are a few small things I need to finish up but she's roadworthy!





I can finally relax at home in the evenings and get sleep before I go to work, it's great, but I have a sickness and will be looking for another budget build of some sort hahaha. This time maybe a bagger, who knows.

 

Very nice 8)

 

It doesn't look like you have anything past the 4 -1 collector, did you end up rejetting? If not how did it run with the pods and no muffler? That is one beautiful ride, I bet your new neighbours are thinking the same thing too!

 

QH the bike looks amazing im going to start to put mine together this week i love the silver paint nice choice

 

Mike - I actually had to pull the carbs as the float was sticking and found that the seat wasn't screwed all the way down. I looked and it's jetted at 110's and 40's. I haven't put enough miles on it to know where I need to be, but we're going to try the pods/open header with that set up.

P2 - The silver was a last minute decision, I like it a lot.

I have a future bike builder diggin' it too.

 

damn that thing looks sick!

 

i hope mine turns out as nice. i am just starting on it tho.

 

Thanks fellas! This was all done on a budget, I have less than 1500 in it. That's the cool part IMO.

 

Perfect!!

 

That turned out beautiful!! Be proud!!

 

Dude that thing is sick!!!!! I'm glad to see the pics of it once again thanks for your help and input on mine. Lets hope it comes out so good.