To the Maxim I go

Found this 20 miles from me with almost 14k miles on it. In decent running shape, headers a little dented as well as the mufflers. Head had a little leak out the front by the exhaust manifold. Handle bars a little bent, but she started and road ok...

After 2 months and a few $$ she now has:
New 4-1 exhaust, Filter pods, front/rear brakes, all new controls, handle bars, halo headlight, speedo, grips, front and rear wheel bearings, fork rebuild kit, fuse block, turn signals, stage 3 jet kit/rebuild, new engine gaskets, oil filter/bolt, lots of new stainless bolts and hardware, removed center kickstand, powder coated lots of of the bike, solo seat and springs, and high temp black pearl engine paint. I know I am missing quite a bit.. so I am sorry.

To do:
Currently welding up rear frame and seat springs as well as wiring it all back to work again.
Also will be fabricating a batter box and something to hide electronics. Please advise and help is appreciated!

 

If you intend to have a front fender, you need a fork brace.
I hope you'll be adding a rear fender. The rear tire will be rough on your scrotum if you slide off the back of the seat. All the road debris hitting you in the back won't feel good either.
Of course you may know this already, just saying in case you don't.
Another tip. When welding the hard tail on, You'll want to cut the vertical pipes half circle to insure a strong joint, bevel all the end pieces and leave a 1/16ths inch gap between pieces to have a better penetrating weld. Many people just put the pieces together and weld over the top of a joint, then grind half the weld off creating a weak joint.

 

I don't believe I will put the front fender back on, not really a fan of it. I may utilize my stock rear fender for the back as I do cherish my scrotum!

I will be prepping the vertical supports with the half circle for the horizontal pipe to lay right in for better seams/welds. It looks as if I will have to heat up the verticals to bend them in a bit for a perfect match. I will be utilizing both existing brackets on the rear wheel, instead of welding directly to the brake drum side.

I removed my center kickstand and ground down the mounts underneath the frame nice and clean. Then I chopped off the ends of the center kickstand to use for brackets on the rear frame connecting to the rear wheel.

 

Ok.. wanted to ask before I do it... the rear bottom vertical frame support I will be welding to it to complete my hard tail conversion. It obviously doesn't match the new dom pipe I will fit in. Do I bend the new pipe or the vertical lower supports????? Any advice is appreciated!!

 

I messed up on my earlier post. What I meant to say was, If you don't intend to use a front fender, you'll need a fork brace.
Hardtails are easier on chain drive bikes aren't they? The drum side anchor to frame is in a different place.
You'll want to keep the new horizontal pipes flowing at the same degree as the backbone for asthetics. Some people bend the rear vertical pipes, some leave them at the stock angle and cut them shorter. If that helps. Do a Google search of bobber pics and see if you can get some ideas or visit Thechopperunderground.com. Those guys can be a great help.

 

where do I find a fork brace for the front wheel??

 

Something like this: http://www.jpcycles.com/search/search?Ntt=fork+brace&N=28012733&Ntk=All
Other sites may have them cheaper or you might be able to make your own. The original fender had a brace made into it because these bikes need them.
Was my last post on the frame helpful?

 

Getting my rear hard tail in place... looks like I will have to bend it by the bracket a little before I weld in place.

 

Also found out my Cap bolts on my forks are rusted pretty good. Ordered some new cap bolt O-rings and new air valve O-rings too. Should do the trick as they won't hold any air in them.

 

One cap bolt out.. the other is rusted stuck ...still trying to remove it with penetrating oil.

On the other hand welded rear frame, cut down front fender and painted... also finished my seat springs!

 

hey man nice progress so far. looks like its really coming together. so i have a few question as i am getting ready to plunge into my 82 xj 1100 bobber project. my first question is where you found your brackets for the hard tail. Also what do you plan to do for wires. are you keeping everything the bike came with or are you cutting some out. any help would be great. keep those pics coming they look great!!

 

http://www.xjbikes.com/forums/index.php?attachments/xj650-center-kickstand-jpg.14642/

click on this link above, or cut and paste.

These are cut off my center kickstand that will no longer be used

 

As far as wiring ... im at a standstill as it has been a little bit of an issue... as I have all new controls on it now. Looking like a spring finish for now.

 

Is that a crack in the frame above the engine on the front downtube?

 

no... it's a factory weld... the lighting makes it look more dramatic than it is.