81 xj 650 chop and drop project

Ok I spend a lot of time reading the forums but don't post much. Lots of great info here and inspiration but looking to do something different. So I wanted to share my project.

Starting point after last years mods

 

A few pics of mods I done last year to lower the bike 3 inches. Plus if you look at the original pics it has about 3" of foam taken out of the seat.

 

These are pics of chopping on day one

Tear it apart




Chop it up



Hard to tell but raked the neck 5degrees

 

Looks good, I take it that it will be a hard tail?

 

what handlebars are those?

 

Actually Streetbrawler it wont be a traditional hardtail its hard to explain but it will sit on about 3/4" of die rubber. I will try to post pics but this is the second bike we built like this and it seems to work well. The rear wheel will be wide open except the swing arm and axle.

Chadall3n: I'm not sure what they are called i picked em up on ebay for like $30. I might be selling them once I figure out the handlebars probably end up bending my own to get what I want, but i will get more pics posted soon

 

I bought a fender on ebay but didnt like the way it rolled the tire so we cut it up and made it the way I wanted it.



Since everything is gone under the seat I bent up a new battery box, the idea is to put studs on it to remount all the boxes on the sides and I still need to weld tabs on it for the straps to hold the battery in but here it is

 

Bobv1LA,
Those shock lowering mounts look almost identical to the ones I made for mine (small world) I have since removed them and just shortened the shock springs 1" instead which works about the same.
Keep us posted on your progess. Hey, it's just about riding time!!!!

 

Hey PainterD. Yea that right side isnt very original you just copy a harley lowering kit the left side takes a little to figure out but its great having a buddy with a machine shop and plenty of scrap steel and aluminum for me to play with. Ive been kicking myself for starting so late because Ive missed some really great weather and could have been riding but I can wait because it will be one of a kind. And I will keep posting pics but right now doing all the little things it doesnt look like much is getting done but customizing isnt quick

 

Ok a little update got some more done on the bike. The rear fender is now mocked up still have to chop the tubing off and shape the fender but its coming along

 

what bars are those? I like the look. Very nice!

 

Really don't know what they are called i picked them up on Ebay. I actually put them in the press and straightened them out so the risers follow the line up from the forks and the bars are straight across the top. Will post more pics in a few days with progress when it rolls out of the shop to be disassembled again for mud and paint. I might try to upload pics of the custom side panels but they have been changed slightly too.

 

It's finally rolled out of the shop and about ready for paint if it will ever quit raining every other day. Would really like to paint without firing up the heaters in Mid May but looks like I might have to. I figured I would post a few pics of the bike so everyone could see the progress, they are crappy cell phone pics but I left my camera at home but should be good enough for everyone to get an idea of what she looks like.

 

how is the rear end supported? you gona put on shocks?

 

^^^^^ I was just thinking the same. The bike looks GREAT! Can't wait to see more.

 

It's an untraditional Hard Tail. If you have ever seen how a mono shock is set up it's the same principle. A mounting point on the frame and a mounting point on the swing arm/axle housing. I trap a piece of die rubber(a very hard piece of rubber) between them. It gives a little so it's not a total hard tail but it's not going to travel as much as a shock.

 

wow, thats pretty cool, if it's not a pain to do, got any close up shots?

 

Well it's not a mod for your normal weekend warrior. I will try to snap a couple of pics but with the bike back together it's all hidden. This is the second bike I've done this way with the help of a buddy, he has a full working machine shop so that helps tremendously. Plus getting to dig through his scrap steel laying around I was able to Fab my custom side panels and make a custom panel to dress up the front neck aaround the tank.

 

I'd like to know more about those handlebars if you decide to get rid of them. PM me.

 

Mine have been straightened out in a press but I PM'd you a link to a set on ebay, it seems they pop up on there all the time.

 

Finally found some good weather without a giant humidity change to spray the old girl's brand new wardrobe on and here is how she turned out. They are bad cell pics but boy does she shine. I will hopefully get better pics up soon but I'm busy tring to get her ready to ride this weekend. WOO HOO I'm so Ready!!!

 

Awesome! Those side covers are amazing, I love that they are recessed a bit. Are they tack welded in place or did you weld the whole seam?

Was it a cardboard mock up that you cut from?

 

I just had a talk with your front fender.

She said she wants a stripe too.

 

Wow. Can't wait to see the finished project. Best looking XJ I've seen (yet).

 

When you get a chance, get some close ups of the rear suspension (like schooter said)

 

Yea I mocked it up with cardboard and there are Gussets welded in behind it. I was just going to have it bolt on but decided on a smooth look on the outside so I welded threaded rod on the back to make mounting pins for a hidden fastener set up. Plus that way they come off so I can easily access all the boxes that are mounted on the outside of my battery box.

 

Haha Rick. I was really undecided if I was going to run a front fender at all and then looking at a stripe on it. The stripe almost took up the whole fender so for now No stripe but after I ride it awhile maybe I will change my mind.

 

Thanks Joe it's my winter project that I didn't start til March 1st so I'm overly anxious to see it finished too. I should be getting it out of the shop and back in my garage this week so I will see if I can get some pics of the rear suspension but I don't recommend anyone try it at home unless you are a competent welder and an engineering degree helps too. Plus drawing it up on a cad program helps too.

 

wow, this site never stops dropping my jaw, awesome

 

This is my favorit xj. Thing is awesome, nice skills.

 

NICE!!!

 

very impressive.... very impressive...

kinda along the lines some of us are taking.. but with your own twist.. btw COPY CAT with the handle bars!!!

 

I am almost speechless. You and your buddy have MAD skills.

 

Some of us live in workshops but..

Please, a few pics of the suspension location and the plating you welded onto the swingarm. Even just a drawing of the assembly and we could work it out from there.

Looking terrific, maybe a thin pinstripe on the front fender?

 

What tank is that? It doesn't look stock to me, but I reeaally like the way it flows with the lines of the neck. Very nice work!

 

It's the stock 650 tank, I looked high and low for a used 750 tank but they were all pricey. So I took the stock tank filled in the sides, and relocated the front mounting points so the lines flowed better. Thats why I built the custom panels on the neck to fill in the void and make it a smoother flow. I think I moved the tank up and back about an inch both ways.

 

Quick update and anyone who has had their bike stripped down will appreciate this. I got the wiring minimally in place to make sure everything was OK. Sprayed a little starting fluid in the carbs and she wanted to start. I was relieved to here her spit and sputter. I was never worried I couldn't get her to run but just relieved that I don't have to chase down problems. Gives me more time to start polishing.

 

awesome.....glad to hear it and can't wait to see more updates. Now that you got the wiring sorted out you'll be able to tackle the rest quicker.

 

I hate "minimully in place".. My first project bike I managed to get it to start with the wiring "minimally in place".. then stripped her back and fixed the wiring properly and the damn thing wouldn't start.. Good luck with the wiring..

 

The extra 5 degrees of rake set it off.

 

I want to send out a big Thanks to Cutlass79500 on selling me pods and getting them to me so quick. They arrived yesterday and installed today and I went for a quick ride. No Headlight or taillight and no guages but wanted to get her on the road and I loved it. Stopped by my parents place and you think when you are an adult you might actually get treated like one. My Mom said " Why's it so low? Why did you paint it white? You're gonna kill yourself on that thing!!" Wow I guess maybe someday I will get treated like an adult, like when I'm 70. She will be on the road this weekend and I'm sure I will be tuning to try and get her as close to right as I can and I will get good pics up soon and pics of the suspension will have to wait til I take off the rear tire again for polishing the rims because you can't see enough to understand the mod.

 

AWESOME!!! you need to post up pics NOW though. They don't have to be perfect....just post 'em up. You're bike kicks ass..

Oh, and I have one of those Mother's too. She just nit picks the stupidest shit. Drives me insane. Stuff like... Oh, yeah I guess it's nice, but why is this like that or why did you do that there. huh.... it's still ok I GUESS.

 

Make the most of your mums.. Mine kicked the bucket 5 years ago.. Nit picking mums are better than no mum, at least she gives a damn!!

Looking forward to seeing the photos, wanna know what the bike looks like in white..

 

How about some updated pics on this beast. It is still by FAR my favorite XJ. I haven't been on the board much, but now that I'm back in Iraq I have tons of time to kill.

Hey, if I get some time off after this deployment what would it cost me to have you help me work on my bike if I drag it up to Ohio? I'd want it chopped, the rake stretched like yours, whatever the hell you dd to the suspension, plating on the neck, side covers, and that SWEET rear fender. It wouldn't have to get completely finished.... just a lot of the stuff I don't have the skillz to do myself. I'll even do all the work if you just point and tell me what to do where.