Cosmetic mods done

I did not rejet after changing to pod and open exhaust. This always causes controversy, people saying "it must run like sh*t"...etc. It runs great. I did buy a colortune and it took a bit to get it right, but it runs perfectly, stock jets. Flip back a page or 2 and theres a video with sound of it starting and idling, revving a little--nice and smooth, no backfire. Maybe I'm just lucky.

As for the cutting, our frames are different, so I cant tell you where to cut. My whole rear half is cut off now, but before, I had it cut right behind the upper shock mount. If you have a welder, cut wherever you want and reinforce it with some gussets if you have concern. If you dont have a welder, dont cut out any welds that might have structural integrity--- those were put there for a reason. Looking good is important, but keeping it safe is crucial. I'm welding my swingarm solid to the frame just for some added security--just in case. I'm sure everything would hold just fine, but I've got the time and tools, so I'm gonna take the high road. I really dont want anything to bend or break when I'm going 100 past a tractor-trailer. Good luck, hope I helped.

 

Thanks for the info. I'll get some more time in on it this weekend, maybe cut a little off at a time and see what I like best.

 

So here's where I'm at right now. After getting the rear done, I felt I hadn't done enough welding and grinding, so... I cut off the neck, added 8 inches of stretch, and 1 inch rise. Rake will be within 1 degree of stock. You know as soon as I got everything squared up and in place, I ran out of welding wire. On Easter Sunday no less. So tomorrow I will wait for everyone to open up and get back to the task at hand. Here's how she's lookin.

 

sorry double post.

 

that is gnarly... some people just know how to have fun with a bike. props.

 

Great idea!! Keep us posted on the progress. I want to see that one when it's finished.

 

Looking good. What are you gonna do about forks?

 

I'm using the stock forks. I'm only going up 1 inch, and I had the forks pushed an inch through the trees, so I figure if I put them back in the stock position, I should be alright. If not, I guess I'm looking for a set of forks. I'm pretty confident though.

 

Kevin.
Now I see they are extended, but at what angle are you now with them out there? Same angle as stock?
I will be keeping an eye on your progress. I really an interested in doing the same to mine now. I can't wait to see how it handles because it's going to look great!! Hat's off to you for your endevors. PD

 

As for rake angle, I'm not really sure of the degree, but it's as close to stock as I and get with a square, level and tapemeasure. My son left his protractor at school over spring break . I just cut the neck off as squarely as I could and measured top, mid, bottom trying to keep everything exactly the same distance insuring it's square and true. It looks like it's on the money, I'm gonna get it a little more solid, then throw the forks on and see how everything looks before I weld the crap out of it. I'm trying to take pics as often as I can, hopefully in 8 pages of mods on this bike someone has gotton something out of it somewhere between there and here. If not, at least I'm having fun cutting this thing up!

 

Alright!
I am pretty much the same way. It's fun just cutting and welding when there's some kind of conclusion to the madness. Anything is possible with the right tools.
Are you planning on moving the top of the down tubes forward to the new neck location? I think it would look better that way and be alot stronger. PD

 

The neck is just tacked right now, I'm going to add 2 downtubes and gusset it. Keep in mind that a good portion of this will be concealed by the tank. I also forgot to mention I'm going to a 21 inch front wheel too, so that will also help compensate for the drop.

 

Inspiration is what a lot of people are getting, i'd say. They see that it is ok to chop a perfectly good motorcycle . Besides what fun is stock?

 

A little more progress today, after a welder breakdown/catastrophe. I added one downtube, and have the other one cut, ready to weld in. Everything seems to look correct at all angles.

 

Looking alot better now. Once you get some gussets in there, it should be plenty strong.

 

Looks great! Gonna look sick when its all put back together. what happened to your welder?

 

Well, I ran out of wire, and after I put a new spool on, it wouldnt work. I had it in a zillion pieces, and it kept blowing fuses, and frying the boards, all kinds of crap. I wiped it off, took it to the store and they exchanged it for a new one in the box, out the door, free of charge. In the end, I really dont know or care what happened to the welder, but the new one is doing a terrific job.

 

Not to threadjack, but I finally got my bike in the garage and did some cutting. I'm making new struts to lower it one more inch. They will be on with more pics tomorrow on a new thread. BTW hope to see your frame done soon, and good luck with the new welder.

http://i229.photobucket.com/albums/ee30 ... C-010F.jpg

 

what brand welder, and what store?

Steve

 

My welder took a dump on me... so I tore it apart and recrimped all the wires.. works great now.. the company used cheap crimp jobbies... anyway.. nice bike man... I couldn't ride it cuz I'm the clumsy guy that would probably get stuck to the spikes on the tank..

 

Holy crap... Nice work Kevin

 

impressive work kevin... i wondered what had happened to your bike for a while there... seemed i didn't see much of it. its always been one of my favorites, not everyone is metal enough to put a pentagram on there tank! hahaha

 

Here's a few shots from today. Sorry for the size, but like my wife says, better bigger than smaller. Seat is propped up wit a strut, I'm currently fabbing the mounts for the shock. The tank is almost there, i need to finish welding the mounts and find 1 of the rubber mounts that has vanished. I'm super pleased at how this is looking so far.

 

Those pictures are HUGE!!!!
That's ok, I can see better now. You did good. It looks like the frame will be plenty strong with the way you have it braced. Maybe put a few gussets between the down tubes and the steering head would be in order? Other than that, it should hold up against a good jolt. The frame sits level so it looks like everything turned out alright. Now to see how it rides!!
That tank looks interesting. Is that bed liner on it? It looks tough (in a good way!)

I managed to get some stuff done today too. I finished the tank I was working on (for a 700 Honda Shadow) and threw some pinstriping on it instead of ordering the stock labels for it. What do ya think?

 

Yeh, that tank looks real nice, great job!

The tank does have the Duplicolor bed liner on it. It's super resiliant and has had gas *ALL OVER IT* and you'd never know. I think I'm going to sheet metal in the whole front end, everything that I added up front and on under the tank. I think it'll be a much cleaner look, and conceal a bit of the old frame peeking from under the tank. '

An after thought about the big pics--- now everyone can see and examine everything all around the shop. Not that I have anything notable, but people are weird like that (myself included).

 

Kevin, its looking bad*ss! You went exactly to route I want to go. That tank sits perfect on the frame! I hope to see her painted soon, what color are you gonna paint the frame? It looks awesome!
I look at this thread everyday and all it does is fuel my fire to build my bike. Great work!

 

What do you use all the old skateboard wheels for?

 

The old skateboards wheels were used for (drumroll please) skateboarding. I go through a set every few months, and instead of having a giant pile of them in the closet, i threw them on a piece of speakerwire hanging from the ceiling. Poor mans art project. I have more skateboard parts laying around than bike parts. Throwing them out seems like a waste, who knows when you might need 50 wheels at once.

 

Kevin.
How does that bedliner stuff work on an engine. I see some of the Harleys with the flat black wrinkle finish on their engines, and I'd like to try something like that on mine. I thing that Duplicolor would look perfect, but I'm not sure about how it can take the heat.
Or has anyone else use it on their engine? Thanks. PD

 

thanx for the close up shots kevin thats exactly what I needed. its lookin great so far cant wait to see it when its finished.

 

I have no idea, it's not on my engine--- thats hi-temp paint. I know under torch it melts right off though.

 

What kind of tubing did you use for the frame pieces you fabbed and welded on? Where'd you get it?

Pretty cool stuff, by the way.

 

1" black steel pipe. Found at any hardware store or scrapyard.

 

haha kevin I just noticed your tire is on backwards. any particular reason?

 

It looks better that way

 

haha nice

 

Grrr.

 

Posting issues.

 

Here's one of the seat mounted up with the shock in there.

 

Lookin good, when are you gonna have it back on the road? You seem to be a pretty fast worker so i'm guessing not too long. I need to take a ride one day to columbus, maybe we can get a group ride together?

 

Yeh, for sure a group ride would be rad.

I still have a *TON* of work to do, although it does seem to be moving along at a reasonable rate. I'm still looking at at least a month, prolly 6 weeks to be safe. I at least have to wait for some warmer weather to do the paint. I'm not trying to hurry anything along, I've got another bike to ride so there's no rush to get it done. We'll see.

 

I feel you on having "a lot" of work to do. I hope my bike will be on the road at least within 2-3 weeks, but this is just the first incarnation. Then I will tear it apart again

 

More giant pics...

Threw the engine back in so I can begin work on the pipes. Also mounted up my ammo box for the battery/electrical. Things are begining to come together, I'm seeing a very very small flicker of light down the tunnel.

 

Might I make a suggestion on the rear frame section ?

 

You're free to suggest anything- it's an open forum.

 

It's starting to take shape now Kevin, very nice so far!!!
What color are the "ammo" cans going to be? That thing is going to look "industrial" when you get'r done! Deffinetly one of a kind. PD

 

The rear frame section has several points that will flex a fair amount in its current configuration. If the modification is strictly cosmetic there is no concern.

Because the XJ is shaft drive there is a torque reaction when accelerating. The swingarm flexes a fair amount, especially on the 700X, Turbo, and 900. It is not the most rigid swingarm ever designed

If you plan to ride it at speed you will need a reinforcement in one place. The stays (long piece added) are good. The vertical struts midway are good. Essentially these are two planes unconnected in the middle. A small tube or gusset between the stays at the same position as the short struts.

A nice curved gusset or a tubing would look good and really eliminate the flex in the rear section.

The other option is to gusset the rear engine cradle below the seat.

 

You might also want to buy some chest kevlar for the one time you need to stop quick. Especially with those awesome short handlebars.

 

KE,

Are you a MGD fan? I think I might have spotted a can

 

Injun--- thanks for your input. My mods are equally cosmetic and function. I want it to look the way I want, but make no mistake, this bike will be ridden. I had never considered that element of flex from the torque of the engine, my main concern was vertical deviation. I will consider the additional bracing, for sure. I also will have a short fender on it, maybe it will help sure up the lateral flex. Thanks again for the input.