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Old 12-09-2011, 07:06 PM   #91
twistedkeys
Utahrd
 
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Joined: Sep 2010
Location: Paiute, Utah.
Oddometer: 159
great looking project mate! I'm def subbed.
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Old 02-20-2012, 10:07 PM   #92
Byrdman OP
Fat guy on a little bike!
 
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Joined: Sep 2006
Location: Streamwood, Illinois
Oddometer: 343
Holy shit, I've been dragging this project on for almost three years!

I'm back working on this beast and I'll have a proper update in the next few days. Teaser: new lathe, lots of stainless steel shavings, rusty tubing, two used spools of welding wire, and a new Corbin.
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Old 03-31-2012, 01:36 PM   #93
IndyChizzle
Spending more on gas
 
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Joined: Aug 2010
Location: Indianapolis, IN by Kessler and Michigan Rd.
Oddometer: 690
Would love to see this project completed. I love the idea of a Japanese naked bike bike turned scrambler.
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Old 12-17-2012, 08:28 PM   #94
Jnich77
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Joined: Aug 2012
Location: Orlando Fl
Oddometer: 593
any updates...lol?
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Old 01-06-2013, 08:01 PM   #95
Byrdman OP
Fat guy on a little bike!
 
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Joined: Sep 2006
Location: Streamwood, Illinois
Oddometer: 343
Progress continues.

I'm a perfectionist so each steps seems to take weeks.

I will get a few pictures up soon but since the last update I have:
Fully rebuilt the rear 30% of the frame to support a set of Hepco Becker panniers.
Extended the entire rear of the bike (frame, tail fairing, undertray,wiring, etc) by 5" to support the huge bags.
Built a custom set of bag mounts that slide into custom made frame receptacles.
Completed the lower engine cradle/swingarm mount.

Stay tuned everyone. I'm embarassed that this project's scope has grown and my progress has clowed to a crawl. By the time I'm done, I might as well retire from motorcycling!
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Old 01-06-2013, 09:39 PM   #96
Jnich77
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Joined: Aug 2012
Location: Orlando Fl
Oddometer: 593
No worries man, the longer it takes you to finish it.. the longer it gives me to talk myself out of doing the same thing to my bike...haha
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Old 01-19-2013, 03:55 PM   #97
wsdbikes
New Max is Mad
 
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Joined: May 2007
Location: PNW
Oddometer: 1,281
you're gonna put your eye out with that.
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Old 05-16-2013, 02:15 PM   #98
davethegoat
bahhh....bah...
 
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Joined: Sep 2010
Location: Walking my dogs
Oddometer: 209
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Old 06-18-2013, 11:42 AM   #99
Lacedaemon
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Joined: Feb 2007
Location: Northern Virginia
Oddometer: 555
Reasonable?

I feel like it's reasonable to bump this and ask for an update once a month... so bump.

Cool project!
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Old 06-20-2013, 02:01 PM   #100
richarddacat
helmet full of Blues
 
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Joined: Nov 2006
Location: land of a new Rising Sun
Oddometer: 3,156
I believe the project will be a candidate for CL, the excuse; "lost interest, no-time to finish".



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Old 06-25-2013, 09:44 AM   #101
Just Max
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Joined: Oct 2012
Location: PA Amish Country
Oddometer: 178
Quote:
Originally Posted by richarddacat View Post
I believe the project will be a candidate for CL, the excuse; "lost interest, no-time to finish".



Makes me sad.. maybe he will post it up here first.. I would be a buyer
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Old 06-26-2013, 09:56 AM   #102
Byrdman OP
Fat guy on a little bike!
 
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Joined: Sep 2006
Location: Streamwood, Illinois
Oddometer: 343
I’m still here guys!
The XR900R project continues to roll forward albeit at a snail’s pace. Two kids, two dogs, two rental properties, a taxing job, a mean ole’ wife, and an expedition style 4Runner build have put the 919 Dual Sport back a bit on the priority list.

Since the last update I have been working on getting the engine cradle, the tail section, and the pannier mounts done.

Here's the final engine cradle.



I’m using a set of KTM 950A Hepco Becker panniers. As you can imagine, their immense size forced some significant changes to the relatively small tail section of the 919. I had to extend the entire rear of the bike 5” which added a ton of complexity.



Once the frame and internal structures were extended, I wanted to clean up the body work to make it look as factory as possible. I literally spent three weeks grafting two tails into one longer one. I laid down probably a mile of fiberglass and sanded until my hands were numb. I still have some cleanup to do but I’m beyond happy with the stock appearance of the new, longer tail.







I then set out to determine the perfect locations and orientation for the pannier mounting brackets. Where the weight sat on the chassis, how it looked, incorporation of the stock undertail, where my legs would be, the location of the kickstand, easy removal of the bags, easy removal of the support brackets, etc... All these factors were taken into account. I really wanted the install to be clean. I have seen other add-on pannier brackets and often, they look like they were a total afterthought. I decided to use a tube in tube, slide in type assembly to mount the brackets.











And as she sits today.



I did however find my inspiration at the local Toys-R-Us!

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Old 06-26-2013, 10:00 AM   #103
XR4EVER
919 excuses to ride!
 
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Joined: Aug 2012
Location: Post Falls, ID
Oddometer: 1,057


It lives!!!!!!
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Old 06-26-2013, 12:37 PM   #104
Jnich77
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Joined: Aug 2012
Location: Orlando Fl
Oddometer: 593
Definitely one of my favorite builds...ever!!!!
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Old 06-26-2013, 12:56 PM   #105
aposaric
Garden mechanic ;-)
 
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Joined: Jul 2007
Location: Zagreb, Croatia
Oddometer: 270
Quote:
Originally Posted by Byrdman View Post

And as she sits today.



It's alive :-) I wondered what happened to this bike :-) Do you have any plans, or rather, the time to finish it this year ?

Keep us posted, really cool thread to read and watch pictures
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