My '85 XJ700 Bobber Chopper Build

How the eff did you get those side covers to a mirror finish!
I've never been able to achieve that

 

Nice man!

 

There is a bracket on the left side of bike that i didn't cut off because i can attach a coupler nut as a spacer and put the bolt from the inside of the canister to hold it in place. The lid will be facing to the right side and in place of the knob im going to attach a crest or a junction produce metallic blue wheel center decal... I have an extra one if you want it.



Maybe this pic is bettero



Also to keep the lid from openin up a simple small PK screw will do the job just fine... One at 5 o'clock and the other at 11 o'clock (looking from right side)


The crankcase breather filter i got on ebay for $5.00 Free Shipping from Walnut, CA

12mm Crankcase Vent Air Intake Breather Filter Blue - Universal

Ebay Item# 1512 4390 2834

I separated the item number so it would be easier to read

 

I wet sanded the covers with the following grits

500, 800, 1500, 2000, 3000 cloth disc

Then i took a yellow buffing wheel only bc the white ones are no good..
I attached it to a drill and used the green , blue and then finished with the white stick... ( Harbor freight tools)

After that i used a microfiber polishing cloth

That is all it takes.. Just take your time and wear gloves because it gets messy

 

p.s nice bug!

 

8O
My initials are JP (in case my Photobucket links weren't enough of a give-away). I may just have to take you up on that offer. Thanks.

Also thanks for the crankcase filter info. I'll be snagging that one soon.

 

Nice job on the coffee canister for your extra wiring! I'm also going to be trying something like that one mine with a piece of 4" pipe and some caps

 

This is what i have done so far with my bike

This is how I cleaned up my wires.. I used a vintage aluminum coffee canister 7.5" × 5" diameter
Let's see if I can post pics from my android cell phone



Now I cleaned it with Baking Soda and Lime Juice , then wet sanded and buffed the Coffee Canister







I made the hole with a Unibit or Xmas tree drill bit


Then i used a rotary bit to open it up some more to put the cables and wiring through


I used a Coupler nut to serve as a spacer and at the same to bolt it to the bike and a bolt washer combo on the inside to hold it together.




I covered the lid hole with the Junction Produce wheel center cap decal.. blue is my favorite color


All the wiring is inside nice , neat and tucked away


Here is the finished product with the custom tread plate battery box i made...




The battery box i made and i used my vice and 2x4 to make the bends

Made the lines where i will cut and then bend the pieces on the edges to form the box.. have not figured out yet how to keep the sides together. Maybe i will use Liquid Nails and then the treadplate will put on via Double face tape.




Used flat bar to hold the aluminum in place on the vice so i could get some good radiuses and not have the piece crack on me while bending over... the wood piece is great to bending the aluminum plus it wont scratch it.

 

I extended my wires between 16" t0 21" because of the 15" Apes



Applying some good solder and shrink tubing to keep nice clean and neat... I am a bit of a perfectionist.

 

I am adding these flat bars only when my wife wants to ride with me...

 

There is a reason those fins are designed on that part, heat dissipation. In a small container that's sealed off with zero air flow you may want to keep an eye on how hot it gets.

 

You can't put solid struts onto a moving swingarm. The way you have set that up you are going to cause serious harm to your wife.
The fender has a solid mount at the frame, the swingarm pivot on bumps and the shock take the impact. the strut will transfer that impact directly to the fender and either snap the fender off or impale your wife with the strut. so unless you make the swingarm a hard tail by taking off the shocks and replacing them with struts you are looking at a catastrophic failure with that set up.

 

Battery box looks great. You need to remove the regulator/rectifier from that can or create an air flow because it gets hot.

 

Yes , i am aware that the fins are to dissipate heat but i didnt think that it would get that hot.... It sucks because i wanted to hide all the wires possible.
I have to think of another solution.

 

I'm using Harley sporster 11" eye to eye progressive shocks and they have nominal travel but i can see that it can pose a problem i just didnt think it would be that catastrophic... I guess i will make some 1/4" thick strut bars.

 

You could mount the regulator/rectifier on the side or end cap of the canister and run the wire into the canister thru a drilled hole. Just as long as you get a good airflow across the fins.

 

For the rear fender, you need something like this: http://www.jpcycles.com/fender-struts-and-covers

 

Hey man, thats a nice chopper project going on there. I see you dont have a speedo. On my XJ650, i tried disconnecting the stock speedo and it doesnt turn on the bike. Can you tell me how did you do it?
thanks

 

Hi Zach'Riah. Congatulations on a very interesting build so far. I'm really looking forward to seeing the finished product and hearing all about how she runs. Keep up the good work.

 

Which ones do you suggest from the link you posted?