81 xj550 project

Fiberglass can be stapled. It won't crack unless you use a really shitty resin or make the seatpan too thin.

 

since i am doing my wiring all over again, i figured i come up with something that would tidy up the connector mess i had in my battery box.
et viola... a home depot flash light turned connector hide-away box. just needs a few coats of spray paint and a lid.

 

Great build. Especially for being on a budget. Following.

 

Not really a budget build I am afraid. Replacing most of the parts etc. I will list every single item when done.

And btw, it is "et voila". Et Viola is a joke my dad used to make when I was younger. Viola is a girl's name. Anyway...

 

Just realized that I still need to figure out where to install the ignition...
Don't want to put it where the horn is though.

I have the original replacement t but think there are smaller options out there. Will stop at auto parts tomorrow and see if they have anything. If not, online order

 

Found a small one at dime city. Yay.

 

Decided to put ignition in that little triangle in front of the horn. The tiny ignition came in.



I also decided to go with a new LED tail/brake/turn strip for back. Here the bracket am working on:


Still fighting with wiring but have everything laid out and working, just need to redo it nicely.

 

well, after looking at the bike again, i decided to scrap the little container box. nobody will see wires anyway because of the rear fender and the side covers.
i am also no longer sure about the contraption i build for the tail light LED.

The tiny ignition is installed but i had to relocate the horn. it is now above the carbs.

 

All the road detritus, spray, bugs... Etc---- will blow right into your ignition switch.

Make some type of hinged, and sprung, cap for it to both protect it and hide the key.

Also, attach a lanyard of some sort just as a safety in case the key should vibrate loose and fall out. Don't tell me it can't come out when it's switched on-- I seen/had enough that the key slide right out with the bike running.

Dave F

 

Tank and headlight bucket finally came back today.
Still need to finalize wiring before I put on the tank and take pics. But it's a beauty. You won't be disappointed.
Just wish I had the seat done or at least in the making. Need to take care of that tomorrow.

 

Wiring is done. Here the fuse box.



Tank and headlight are on. I will have to adjust the clipons a little. They are not touching but close.
I am not too happy about the headlight bucket. I should have gone with black. Thinking about having it repainted.

 

Also need to add the badges on the tank again. I will have to come up with a name and have it made.

 

Wait until you have the bike complete before repainting the headlight bucket. I think it looks good. Maybe think about an accent stripe to help visualy shorten the length of the bucket.

 

Yeah. Tank badge will break it up, maybe different fork ears/clamps. The nice ones are too skinny. Not important. Have other stuff on my list first.

 

I think I'll try a shorter/not as deep headlamp tomorrow but would need to find a new place for speedo/replace the existing one.
The blacked out bike makes it look bulky and the long headlight doesnt work anymore. Didn't appear like that when it was a rolling frame with less black.
Also need to install front turns. Wires are already there and working.
non-wrapped headers would look nice but not spending money on that right now. Already too deep in.

 

I just realized why I don't like the look of the long headlamp bucket: the new brackets move it farther away from bike. Swapping back to the other ones, the ones I had in my test setup, pics on one of the previous pages.

 

finished up most of it yesterday. last parts are ordered (fuel shutoff, tach plug, front and rear brake switch). after that, only thing left is the seat, building a license plate holder and connecting the tail/brake/rear turns. oh, and putting the chain on, which i have never installed before.
i was wondering about the front brake switch: while i am waiting for the actual connector, i attached the wires to the pins and the brake light came on. now, that is a good sign i guess, but the light was on no matter if i applied the brake or not. my thinking is that it should only come on when that little piston is actually pushed in, no?
or did it not work properly because i hooked up the wires straight to the pins and the actual switch would take care of the correct behavior? just curious.

 

I don't have an answer to your question but I wanted to compliment you on your build.
Been following Since I joined this forum and I'm very impressed with your work and your descriptive posts.
I'm very excited for you and to see your finished product.
-EM

 

Thanks EM. Glad you like it. Yes, so far it came out nice.
Reading my previous post again, I think I actually just found the answer. I think the trigger has nothing to do with the piston but with that little push in button which is facing forward. If the brake is applied, the lever no longer pushes it in and the light come on.
when I tested last night, I did so without the lever installed and completely ignored it. This meant the button was always in the "on" position. I will try again and this time press it in. That should turn it off.

 

Changed headlamp bracket which brings the assembly closer to bike. Much better...
I also put on flush turns for now, might swap them at a later point.