my winter project 81 650 maxim

I got a start on my project tonight. Been planning for a while. Thought I'd share here. Be patient on the updates. Cash is in short supply and I'll do things as possible.

First, here's where I'm starting:

Front



Side



Muffler was temporary after the other one fell off.


My plans:

Forward controls
Fenders similar to the old indian style fenders. I've ordered trailer fenders to hack up for this.
I've got a 750 tank for it.
4-2 custom exhaust
Tractor seat:



I need to pick a paint color eventually and I'm really going back and forth on that. Leaning toward a gunmetal metallic as I like the steel/metal look.

Anyway comments are welcome and maybe I'll inspire someone. I've gotten plenty of my inspiration off of this website.

 

oh and my off cast parts are for sale to help fund the project. See the thread here: http://www.xjbikes.com/Forums/viewtopic/t=22149.html

 

Quick update.

Trailer fenders came in. I plan to split them down the middle, then use the radiused edges for the front and the sharper corners for the back.



Side skirt blanks:

 

dude those seats are comfy,get it sand blast for the better paint finish..

 

Is that a 4-1 exhaust, i see you want 4-2 if you are willing to sell I may be interested.

 

Street it is a 4-1. It's not in great shape and has a reducer welded to the collector. I can get you a better pic in the next couple days. I was planning to cut the head mating ends off the pipes and use those to fabricate my own from there back.

Seat has been cleaned already. I used a wire wheel on it. Took some time but it's cleaned up and covered in WD-40 to keep it from turning back until I pick paint.

 

Looks like you got a real nice bike to work with. Nice and clean and straight forward. Would love to hear about your progress with the forward controls when you get there.

Test drove a Harley with them and really liked it.

Rob

 

Yeah I rode her all summer. Just looking to make it look nicer, a bit different and more comfortable to me. I'm 6'4 so the standard controls are a little too close to the seat for longer rides.

 

Wanted to post an update...

Not much to update I'm afraid. I took the stock foot controls, pegs, and peg brackets off. Almost have my forward control design ironed out. Then I'll get the pieces ordered for that. I'll post a CAD image tomorrow after it's done.

Pegs, brackets, crash bars, etc are all for sale now.

 

Ok so here's some progress.

Forward controls drawing almost complete



I can share the CAD file if anyone is interested. Eventually I'll have a fully dimensioned plan with materials list.

Rear fender starting to take shape. The right side had to be notched for the airbox.



View from the rear. Fender fitted a little better. Tractor seat sitting on top.

 

Nice project, but why such a wide seat? I guess its ok if thats what your into, myself for my 80 XJ650 project, im thinking about a much narrower seat. Must have somthing to do with function over form.

 

It fits my wide seat. I found the factory one uncomfortable on longer rides. Hopefully this will be better.

 

cool man! This is alot like a build I want to do sometime

tractor seat, trailer fender, foward controls, and then 4-4 exhaust with like 4 8 inch stacks and rain stoppers on each one... then paint it john deere green

Also, I dont know if its possible, but I think an exposed drive shaft would be awesome

 

Schooter sounds like you should just cut two wheels off a tractor.

Don't think you could expose the driveshaft on these.

 

you really can

 

you'll have to cut down the seat though or you won't be able to put your feet down

 

I've given that some thought. I'm going to see how it works out when it's mounted. I'm pretty tall so maybe I'll be ok.

 

i have been there, tried and tested, there are two options
1. Remove your thighs
2. Cut down the seat

 

Did you expose the driveshaft to put a fatter tire on the back, or looks?

 

I just don't see the point of going to all the effort of hartailing thn leaving in the swinging arm, and it means i'll be able to swap in virago wheels on the next build

 

Quick update on my project. I've gotten all my supplies ordered for the forward controls. So hopefully this week they'll be in and I'll get them built.

 

Quick update. Steel for the forwards was/is backordered. Exhaust tube and bends showed up yesterday. When next payday rolls around I need to go pick up a cylinder for my mig and then it'll be time to get some stuff done. Hopefully the steel shows up by then.

 

Your idea pics of the forward controls looks good. Just make sure the plate steel for the brackets is thicker than 1/4" or it will bend too easy. Just sayin'.

 

I've got 1/4" plate for the brackets. I also plan to gusset them onto the spacers. I've been working on them a bit. Also fighting with the landlord of the place I rent because other people have space heaters on when they're not there and then my tools trip the breaker making for a not so effcient work time.

 

Quick update but no new pics. Most of the fab work is done for the forwards. Once those are finished up I'm getting started on the exhaust. I'll have some pics sometime over the weekend.

 

I'm a little late to this rodeo, but you might want to rethink some of the design aspects for your forward controls.

Most notably, the rear brake. As it is shown, when you go to apply the rear brake, you are going to push on the "peddle". When you do, you'll be pushing on the rod that leads from the peddle to the arm connected to the rear brake. If the rod is not thick enough, it will buckle, greatly limiting the amount of force that you'll be able to apply to the rear brakes. All linkages, especially long and slender ones, should be in tension to eliminate this risk.

Of slightly less concern, but still important, is your pegs. I would very seriously consider making them foldable. Turning too sharp or going down a driveway at a bad angle could cause a peg to dig in and put you on the asphalt.

These are just a few concerns from a degree mechanical engineer. These suggestions may be worth exactly what you paid for them, but I have it off of my mind.

 

pvtschultz thanks for the input. I've thought about that before. The rear brake link is only going back to the original pedal pivot to cut the length down. I think what I've got will work. I'll find out this weekend.

For the pegs, I've got them higher up by about an inch in the front then the highway pegs I had on before and I never got a highway peg in the ground.

I'll keep everyone posted on how it works out.

 

Can't wait for pics on exhaust :wink: . Still have the same plans?

skillet

 

Yeah same plans. I'm concerned with clearance between the forward controls and the pipes. So once the forwards are on the exhaust will get started. I'm spending atleast a full day on it this weekend so should see some good progress.

 

An update with photos this time. Got the seat mounted up. The forward control plates bolted on to check that they were where I wanted. They are. So next up is finishing the pegs and the links to the shifter and rear brake. I also put my 750 tank on to check that against the seat and mount. I am able to get my feet down with the tractor seat as is so I'm pleased with that.

forward Control bracket:


Front of the bike with control brackets.


Bike from the back:

 

Update time. Bathroom remodel is done. Weather is good. Got some time to go get some work done.

Forwards are finished.



They work well. The shifter was a pain. I cracked one cover popping off the old shift lever. New one is one there and the gasket changed.

Fender for the rear stiched togther. I need more welding practice. Oh well the grinder will fix it.



Got the side skirts on and made mounting tabs. Now that I'm looking at the pictures I need to rotate it down some. So the tabs will be moved.



Also here's my pair of XJ's.



I've also gotten the valves check and I'll be ordering some shims tomorrow.

Updates should come more often now that I'm done working in my bathroom. You've really got to keep at it when it's the only one in the house.

 

All right. Here's another update. Seat and rear fender fab work is all done now. New 10.5" shocks installed. I've got the front fender mostly done. Pics of that later. Exhaust is getting started sunday.

 

the tank looks great. That IS what I need to get for mine. I'm digging the tractor seat too.

 

i like it - what are you doing with the back frame? gonna chop it off past the springs? i maybe didnt read it back in the thread - thought i read the whole thing tho
just curious.

cool tractor seat too.

 

I'm going to leave it. I'm mounting my bullet brake/turn/tail lights in the hole at the very end.

I owe this thread some updated pictures. The front fender is done and I have the exhaust started. Paint supplies arrived today and I'm going to spray out a test panel when I get some time.

 

Yes you do. :wink:
Curious to see where it's going.

 

All right here's the update. Exhaust is fabbed. I need to decide on a length and build a mount at the back for the mufflers. Front fender done.

Next is to begin the body work. That should start monday. I have more time to work now thanks to a cut back at work.

So here are the pictures:

Side with no tank



Front no tank:



Side with tank:



front with tank:



I don't think I mentioned it before. I've got duplicolor blue metalcast for the paint with gunmetal vinyl flames for the tank. That'll get on here in a couple weeks.

 

WOW! This is going to be sweet! I like it!

Rob

 

Hey I would love a copy of the CAD drawing. I was planning on starting my own but if I have a place to start that will make my life easier.

 

Shoot me a PM with your e-mail and I'll send it out to you tonight. It's AutoCAD 2009. The hole dimensions on the plates are fairly close I haven't had a chance to modify the file to the final dimensions.

 

Next update. No pictures though I forgot the camera.

I have side covers made I will be making mounts for them tomorrow and will get some pics of the bike when I do.

The forwards were modified to allow the footpeg to break away and are remounted to the bike.

The exhaust fabrication is complete. A little weld clean up and then it's time for the exhaust wrap.

I need to complete my new rear wiring harness and mount it to the inside of the fender then it'll be time for paint.

 

where are you going to put your license plate/brake light? If you're going to make a sidemount dealio would you be interested in making two at the same time and selling me one?

 

The plate I've mounted with the original bracket so that the bottom of the plate sits flush with the bottom of the rear feder.

I'm lighting it up with these: http://www.customdynamics.com/illuminat ... _Tag_Bolts

I bought the black ones with the rear facing red and tag light combo. I'll have pics of the plate mounting and tail lights tomorrow.

 

cool.... I still have to figure out signals, bake/license plate mount, and gauges.

 

Here are the picture updates.

Tag location with the LED tag bolts



Front:



Side:



Rear:



The pipes look a little crooked in the picture but the bike is on an angle.

 

what are we getting ready to paint here? I haven't done anything to the XJ bike, but the XJ HEEP got a LOT of attention today. I now have a passenger floor I still have a few small patches to take care of in the back tomorrow and then this weekend I'll have time to do the bedliner and attempt to fit the WJ leather seats in it. FINALLY! some progress.

 

What beadliner are you using? I did the herculiner about 5 years ago. It's ok but without carpet it's hot! Wear gloves! and if you need a laugh goolge herculiner and hootus.

I've got passanger floor on the list there's a nice new hole in the back infront of the rear seat and my patches are starting to run into other patches.

For the bike paint I have duplicolor metalcast blue with the metal color groundcoat with some gunmetal vinyl flames for the tank. That I'll then clear over. I've got to sort out my rear wire harness holders in the rear fender then it'll get torn down for paint.

 

Will the blue mufflers match the tank and fenders?

 

The mufflers are tape wrapped to keep the chrome on them from getting dinged up and the exhaust is going to be wrapped and painted gunmetal too except the mufflers.

 

hahahaahaha....blue mufflers

I need to get some wrap for my exhaust too.

I'm using U-POL Raptor for the bedliner. I used it on my TJ and LOVE the stuff. It comes in a kit with the gun and goes on easy as shit. I got all the patches done today, but no way to get to the store for more supplies until the wife gets home. I want to finish sealing all around the patches on top and underneath. I'm using a window adhesive/sealant like you use when installing a windshield. It was cheaper than automotive adhesive. Then I want to get it undercoated (rattle cans) and the inside primed. I'll spray the bedliner next week, but I want it all protected for now. I just have to decide if I'm going to buy FatMat to line the floor with to battle the heat or if I'm going to just see how this aluminum coating for roofs that I bought at Home Depot for cheap works. I don't know....

Hurry up and get that paint done. I want to see how it comes out.