Mad_bohemian's VooDoo '82 xj750 Project-FINALLY COMPLETE!

Re: UDPATED 04-18-09:'82 xj750 Project continues....

Plumber, I have an 82 Maxim 750. In your pic yours looks the same. Remember , the large holes in the red circles were the same size as the holes just below them that are on the same flat surface....That's how much I opened them up.

Oddball, I have never had this bike all together yet...but when I gave it a 'test sit' it felt pretty good....

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

Just got my frame back from powder coating!! Looks fantastic!!! Found a local place that sandblasted and coated the frame, swingarm,side kickstand,center stand,and swingarm brace for $175 8O
I was going to go with a basic black but they said they could do it in what they called "silver veining" for the same price. I had them do the center stand in black because I don't think I'll be putting it back on the bike, so I figured when I sell it the new owner will love that it looks brand new!!

The place is called Custom Powder Coating and they're in Grand Rapids. Most other places I found wanted over $200 (some as high as $245) , and that was for basic black! If you wanted other colors, that was extra. Custom told me that it didn't matter what color you wanted, if they had it in house, it was all the same price!!
Great guys to work with!! I know who my pc source around Grand Rapids is from now on!!!
Here's some pics..

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

That silver veining looks really really nice.

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

Bohemian that looks great....how involved is it to remove the drive shaft from the swingarm? Did you have to replace any bearings? I should probably look at my manual....

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

Diggin' it. I'm a bit confused as to the way the bars mount... does the 650 and 750 mount differently, or am I just looking at things totally wrong? Look forward to seeing the progress!

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

The 1982 XJ750 Maxim bars are sort of in a world of their own (actually, pretty much identical to the XJ1100 bars), with lots of little special parts. Lots of them.

The 1983 XJ750 Maxim went back to using the "conventional" style bars, same as on the 650 Maxim models.

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

Thanks for the positive comments guys! I'm definitely gonna have to think 'outside the box' for a paint scheme on the tins when the time comes....

Dead, I had pulled the motor, so when I removed the swing arm it had the rear tire assembly still intact. it's just 4 nuts that have to be removed and the drive shaft stays with the rear wheel and just slides out of the swingarm casing. The only bearings are where the swingarm bolts to the frame.

Sorry updates have been slow in coming....I've been busy trying to acquire a cnc machine. I finally got a bridgeport series II that just needs a limit switch replaced. Now the next step is figuring how to get a 7'6" 5500lb machine through a 6' 11" garage door 8O .If I can get rid of some stuff around here I think I'll be adding a third 8' rollup door to my garage . That should make things easier...Then I have to build a 3phase converter.....it's always somethin'. But I can't complain seeing as how I got the cnc machine for only $500. Once I get her up and running the first job is cutting fender struts for this project, then I'll start making forward control mounting plates for the XJs!

p.s. the really nice thing about the silver veining powdercoat...it hides my less than stellar welds REALLY good!! 8)

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

Just wanted to say that this is by far THE most impressive XJ project I've seen by far. I'm always impressed by the ideas that members here have, but for me the projects generally aren't the style as far as looks that I like.

This one makes me want to squeal like a little school girl.

It's not outside the box, but a metallic flake paint job would be gorgeous on this bike.

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

I am giving serious props for the build so far, Mad. And +1 on the metallic flake paint.

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

First let me say your doing an awesome job! I'm a newbie here & still in the hunt for a specimin for my 1st XJ chop.

Are going to run stock shocks or something else? How much have you lowered the rear?

Oh I can't wait to see more pics!!!!!!!!!!!!!!!

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

1st of all, I must say that it looks good.
2nd, what gauge cluster are you going with? or are you going to keep it clean with only a single speedo or something.

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

I went with 11" shocks which, if I remember right, lowers it by 2" . As far as speedo and tach I haven't really decided yet. A LOT of my time has been taken up lately getting my cnc machine up and running. I'm about 90% there with that. I may just go with the stock speedo this year since my tentative plans for headlight are this...



In which case I'd be lookin' to use this for my instrument cluster.



Since it's a little pricey I may have to wait till next year on that idea though. Hopefully by week's end I'll be machining my fender struts... :wink:

 

Re: UDPATED 05-27-09:'82 xj750 Project continues....

WOOHOO!!! Got the prototype strut finished!!! I used a piece of 2x6 pine and since I can only turn about 3500 rpm's (no high speed head) the cutters left a lot of 'fuzzies' . But at least I can test fit and make the needed changes The wood was also about 1 1/2 inches too short , but the tail section is the area I was most concerned with.

The model..


The prototype....




I didn't cut the styling groove or the logo in...I'll save that for the real thing. Wow...between learning how to build a rotary phase converter, wiring the machine, learning the CAM software, learning G-code for the machine, figuring out how to get the machine communicating with a laptop...my brain needs a vacation!!! 8O

Now just have to make a few minor adjustments, then on to cutting aluminum!!!

 

Re: UDPATED 06-27-09:'82 xj750 Project continues....

Mad....do your models have to be in .cad format? Or are there any other format your machine will use, because is your willing to take on other jobs later on down the road....Ill start modeling... hehehe

 

Re: UDPATED 06-27-09:'82 xj750 Project continues....

Dead I could use a .stp (step) , .igs (iges)or .x_t (solid) file format which most CAD systems can export , so start modeling!!!

 

Re: UDPATED 06-27-09:'82 xj750 Project continues....

All I can say is WOW!!! That bike is looking awesome! And I don't usually go for custom bikes! Good work!

 

Re: UDPATED 06-27-09:'82 xj750 Project continues....

Time for an update
Finally got done painting the engine. Pulled the head, cleaned her up real good and used some high temp ceramic paints..



Got most of the covers on. As soon as my metric feeler gauges come I'm gonna check valve clearances, make any adjustments then pop the motor back in. I'll try to get another 'mostly-assembled' pic of the motor tomorrow.....




With the aid of fellow member lowlifexj , I think I got the new controls wired to the xj harness. Once I verify everything works I'll throw up a wiring schematic for those interested.




Finally decided on a front fender!! WOOHOO 8) That came in on Monday. Since the mounting bolts had a 6" spread, I needed to fabricate some front fender brackets. So I modeled some up...





Took a .250 think 4x7 plate of aluminum, threw it up on the ol' cnc and milled then out , bolted them on to the fender and slid her in....




Still working on machining out the rear struts...got one about 65% done...it's frustrating when you have the time to do the work....but not the funds :? I'm running out of things to sell too!! 8O lol Not stressing about it though, I just decided I'd push back the finish date to some time next year... 8) ... how long can you work on a project before it officially becomes a hobby?!?! LOL

 

Rear fender struts machined...

Finally got both the struts machined !! Woohoo
Had to rework the backside so they have a nice tight custom fit. Here's the right side all fitted...



Took the right side strut and finish sanded/buffed/and polished. The left side is is fresh off the machine 8)

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

Jealous? Yes I am. I want a CNC at my disposal.

Looking good man. Keep it up. Can't wait for more updates.

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

excuse me for a minute, ive got to wipe the drrol off my chin and shirt

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

That painted engine looks really amazing. I think I'll do VHT ceramics on mine as well this winter! Thanks for the pic.

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

Brian, Holy fit that thing is sooo sick looking 8O 8O same style I was going for... 8) Love the rear fender with the tail light molded into it... As soon as I get my new tires I'm coming over to really check it out. The rear tire just melted off the other day and wont hold air now :? :wink:
See ya soon,
James


P.S. what does GHC stand for??

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

It's the name I came up with for the madness called customising..

Green Horse Customs

why green and why a horse?? Well...Coopersville's mascot is a bronco (a horse) and their colors are green and white.... soooo... green horse

Whenever I mess around with videos they are produced by Blue Chicken Productions...


just my twisted sense of humor...

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

that engine just look amazing........just amazing

 

Re: UDPATED:08-24-09:'82 xj750 Project continues....

I thought Coopersville's mascot was the seagull :lol:

no just kidding I like the name its unique.

 

Getting closer!!!

Well, I got the motor in yesterday and finished wiring everything up. I put the exhaust on and slipped on the HD mufflers I got last fall just to see how it will look. I'm not totally sold on the mufflers yet. I'm thinking of trying something simple like the chrome turndowns Strat did on his 85....what do you guys think??




I was able to get the motor to turn over jumping the start solenoid w/a screwdriver and they seems to have a really nice sound to them....so it's a toss up right now...

On to the wiring. Here's where it's at right now.
The gauges power up fine. The horn works (all important :roll: ) , the LH signal works,the RH doesn't, the brake light works, not sure about the headlight since my old one doesn't work, but I get nothing with the start button...here we go again.... :evil:
However....... I found this laying in my pile-o-parts...

About 6 1/2 inches long, I'm sure it's a ground strap but I don't remember where it goes. Right now I have the neg- from the battery grounded to the motor...which as I type this I'm thinking.."That's not right you dope!!" So where should this ground strap go, and where should the neg from the battery go. I took tons of pics before the teardown, but as Murphy's law has it...none showed the wires in question... DOH!
If the bike is grounded wrong, would I get the results I'm getting??(some things work, some things don't)

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

ya, turn downs may look better, those things, idk. I gota say though, that seat looks like it was made for your bike, i like it

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

That's a frame ground, goes from the TCI bridge plate to a tab on the frame near the chain lock storage box........

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

Absolutely love that custom rear fender. no more flying mist in the back. got a template for it? or did u hand make it? Chacal nailed the loccation for u. looks like you can polish the chrome off a bumper hitch. mighty nice!!

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

harley mufflers don't look bad by any means but I think the turn downs would look a bit nicer.

i'm a bit biased though.

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

Those "Points" that the Front and Rear Fenders come too seem to visually oppose the rest of the Bike which doesn't have a pointed look going-on.

Having points that low on the Front Fender can be dangerous. A piece of debris picked-up by the point could be bad news.

The rear Fender's straight line looks out of place. That flat line under the seat needs a contour.

Do you see what I mean?

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

Something more like this Rick?

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

OK...So I'm spending some spring-break time in the garage tinkering on Maxine and I'm not really sold on the direction I was going with the exhaust (see previous pics in thread) . First I thought about just taking the the pipes 2 per side, straight out the back side by side, bumping them up to 1 3/4 dia....kinda like a shotgun look. Well I spent quite a bit of time yesterday running around town trying to:
A) Find adapters that would fit to go from 1.5 od to 1 3/4 id.... OR
B) Looking for a muffler shop that could flare pipe for me...

Nothing...
So after spending the better part of the day putting about 75 miles on the car yesterday, today I thought I would run up to the repair shop in lil' ol' Coopersville 5 min away. Talked to pipe-bender and told him what I was looking for and he says yeah... I can make a flared adapter to fit your pipe...then he starts telling me how he made a custom exhaust for his buddies quad... :idea: "Let me get back to you on the parts" I told him...

So now the wheels are turning..came home and photochopped some exhaust onto the bike....(this was the only side view pic I had with no stock exhaust in it...) So I am thinking later this spring to take the bike into town and have my new friend bend me some pipe. Plan at this point is to have the inner pipe swing out and under the outer so the pipes would be vertically stacked at the ends...

Feed back guys... yea or nay ?? or what about just straight thru shotguns side by side??

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

I like the second Photo

 

Re: UDPATED:08-29-09:'82 xj750 Project continues....

wow...it took 100 views to get a response!! lol...geesh..maybe you guys aren't as opinionated as I thought..... NAAAAW!!!
Thanks Tcoop

Well here's something else I got done today. Finally finished altering the mounting brackets for the fairing I picked up from evilbay. It has a windshield but it's way too big right now. I'm going to cut it down so it more like a sport bike type windshield....The headlight is just sitting in there. I'm sure I'll have to fab some new mounting brackets for that as well. You can see the 'shotgun' straight pipes I was thinking about in the last pic.




Like it? Love it? Hate it?...or as one of my Profs would say " Questions, comments, criticisms, critiques??"

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

I love the look your going for and agree with tcoop the angle cut on the pipes look better.

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

nice work man. I like the direction your headed as well. As far as the pipe set up I like the second pic. Is there any wa to include the sharp trailing edges of your fenders into the look of that fairing your installing??

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

IMHO this makes 3 for the angled cut...

skillet
BTW unless I've missed something, how would the kickstand work if you chose the shotgun style

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

8O

um...that's one of those aroundtoit design problems....you know... I'll figure that out when I get around to it... :lol: lol
Good point though. I would probably have to alter the kickstand. I'm liking the slashcut look the more I look at it too

I don't know, but it's a good idea. I'll have to take a look and see what I can come up with...

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

I like the faring but I think your right about cutting it down some. Maybe cut it to complement the fenders some how.

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

Is this too much or about right...

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

Your bike looks great. I say go with your gut and try not to over think what you like. Great Job!

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

unless I've missed something, the kickstand is on the other side of the bike and would work as it always did ;0)

 

Re: UDPATED:03/25/10:'82 xj750 Project continues....

Well the dual straight pipes would be on both side of the bike, but I'm pretty sure I could tuck them close enough to the bike to miss the ks. I have been looking at this and am considering a sort of combination of both versions. My outside pipe will be a straight through shot, and the inner pipe will have two 45 deg bends with a short straight so it can come out above the outside pipe. It will look like the photoshopped pic with the outside pipe on the bottom and the inner coming out on top.
This will also help reduce the cost of getting pipe custom bent (they don't call me stingy for nuttin'!!)

 

Re: UDPATED:06/14/10:'82 xj750 Project continues....

Well it's been a while since I have been able to spend any worthwhile time out on the project bike. got two weeks before summer classes begin so I decided to spend some quality time with my other girl (don't tell the wife ) Decide to get the get the 'exhaust from he11' finished. yikes! I had no idea the can-o-worms I opened with that idea.
I went with the vertical stacked pipes with the change of having the outside pipe just a straight pipe with the inner pipe coming out and above. That meant having two just pipes bent instead of all four. So I went up to the local car repair shop and the guy there bent two of the pipes with a 45 deg elbow, a 2" straight section then another 45deg elbow, and two 3' sections of straight 1 3/4 dia. pipe. Then he made me 4 adapters that flare from 1 1/2" (that fit perfect on the ends of the header pipes) to 1 3/4". Everything out the door for $60. One of the first things I found out when I started fitting things together was that the header pipes were angled wrong for what I wanted to do. The ends of the headers were at a downward angle instead of being parallel with the ground. Then I noticed that instead of being like a flat letter 'C', they were skewed and pointing inward to boot. Well...to make a long story short I decided to do the job right.I went and picked up a tubing bender at Harbor Freight and got 8' of 1 1/2 exhaust pipe. I measured the header downtubes being about 20 deg from vertical which meant I needed a 110 deg angle from the header downtube to parallel with the ground. Cut my self a 2' piece of pipe and started bending





The tubing bender was pretty cheap... I got two and 1/2 pipes done and it broke (stripped the set screws :roll: ) So I took it back and got another one to finish the job with. It worked great once the pipes were bent. I could tack weld them to check position and angle. I added about and inch of length to the downtubes so the exhaust wouldn't be right against the bottom of the motor. I was surprised to find that the header pipes are double walled pipes1 ( That explains why it was such a cluster *#ck trying to heat and bend them! 8O )
So I got the downtubes welded and cleaned up then took them back to my favorite car shop dude and he flared the ends so the fit nicely into the 1 3/4" dia exhaust ..and he did it for free!! Very nice guy!!!

So everything is fitted and all I have to do it weld the tailpipes onto the headers and make the slash cuts on the ends of the pipes and add some hangers that bolt up to the frame. I think I'm really gonna like the way these turned out!



Ended up hacking off the mounting brackets for the center stand to make clearance room for the pipes.



With the center stand gone I had plaenty of room for the pipes





I found a guy locally who can do a high temp (1200 deg) black powder coat on them for around $350....jury is still out on that though.. Tomorrow...start working on the forward controls...

 

Re: UDPATED:06/14/10:'82 xj750 Project continues....

very nice, are you leaving those two pipes staggered or cut them the same length?

 

Re: UDPATED:06/14/10:'82 xj750 Project continues....

No scooter. not gonna leave them staggerd... I went with this look..





Here's a short video of how they sound here.

Apparently I have picked up a leak on my intake somewhere...got that stupid squeaking bird sound again...UGH!!
anyways...


I have hangers welded on for the outside pipes but I am having a heck of a time figuring out where to hang the inners from. at this point the best solution seems to be welding a nut on the inner side of each pipe and then taking a small piece of flat stock and screwing it to each pipe. That way the outer pipe would support both pipes. The only issue I have with that idea is that you would be able to see the vertical brace between the pipes...What do you guys think?

 

Re: UDPATED:06/14/10:'82 xj750 Project continues....

Progress has slowed to a painful crawl....but at least it's still in a forward direction!

Got the exhaust all finished. 60 deg slash cuts



I have a hangar from the outside cylinder pipe that mounts to one of the stock footpeg assembly bolt locations (red arrow). The for the inner cylinder pipes I have a brace that goes from the upper (inner) pipe to the lower pipe for support(green arrow). Now the entire exhaust is rock solid!

 

Re: UDPATED:07/03/10:'82 xj750 Project continues....

Ok, I'm LOVING those pipes. So, how is the bike running after installing them? Did you rejet? Are you popping and cracking all the way down the road? I'm looking at possibly doing the same thing to mine. Any chance you want to duplicate your work if I send you my header?

 

Re: UDPATED:07/03/10:'82 xj750 Project continues....

Do you have a rubber isolator between your pipe mount and the frame? If not it'll transfer the vibration straight up to your back side. And with a steel tractor seat it's noticable......