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Old 04-02-2011, 12:14 PM   #46
hunter_greyghost
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Very good, finished product?
Cheers
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1981 XS650SH "Tourer" [ For Sale - when / maybe?], 1975 XS650B "Adventure" ['Kenny Krazyhorse'], 1982 XL500R 'Project'
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Couldn't afford a 'GSA', so now it's an 'XSA' "I didn't do it! & whoever said I did, is a liar!"
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Old 04-04-2011, 04:53 PM   #47
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Man, I love TIG welders...





Heres the peg attached... I'm going to machine the spacer down so the peg will be closer to the plate, then cut a shoulder onto it for the gear shifter and brake lever to pivot on.





Now I need to cut the angle on the other end of the tube, tack them onto the square tubing, heat the plate up on the back and bend it in a bit so the pegs stay perpendicular to the bike, tack the square tubing onto the mounts, weld it all up, build the shifter and brake lever, etc, etc, etc... Why do I get myself into these things?!
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Old 04-04-2011, 09:02 PM   #48
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Quote:
Originally Posted by dorkpunch View Post
Picked up a new chain yesterday and put it on this morning. Had to also fix the wires that got chewed up by the broken chain, and now my charging light is dimly lit. Still going to have to figure that out.

Decided that since it was wwaaAAAAYYY to loud, I needed to do something about it before my nieghbors got out their shotguns. Built a baffle to quite it down some.

First attempt: just a reverse cone. Quited it down a little, but nowhere near enough.





Second attempt: added a tube from another pipe I had, then stuffed a long thin curtain rod into that and drilled a bunch of holes in it. Then I stuffed that whole thing into my cone and packed the cone end with insulation. Worked great! WAY quite and actually runs better with some back pressure.





I actually used more insulation than in the pic, wrapped about 3 inches up the pipe from the cone.

Guess we'll see how long it lasts!!
Thanks Dorkpunch, you just showed me where to get a muffler for my Zundapp. You'r da man!!!
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Old 04-06-2011, 06:02 PM   #49
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Started on the brake and shifter levers. Found some scrap that ended up working perfectly. Figured out the length, marked out an arc, plasma cut it and ground it smooth.





Have a set of large drill bits at school I've been itching to try out. Took some figuring, but I think it turned out okay.



Lookin a little more like rearsets!

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Old 05-09-2011, 09:43 PM   #50
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Finally got the metal lathe moved back to my room... Spun the spacers down as a test. Worked great!

Before and after.



Installed. Lever moves great, nice tight fit with no rubbing.



and milling the end off at an angle.



Thats it for now. I'm sure I'll get back to it again in another month.
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Old 11-06-2011, 08:17 PM   #51
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So the other "month" has come and gone... Got one of the pegs actually set up.





This side will be a little more tricky- have to come up with some way to hook the pedal up to the brake. The other side will be simple- I just spun the gear shifter around so it points backwards. Now instead of having a 4 down shift pattern, I have a4 UP shift pattern. Hopefully, no more shifting from 2nd, expecting 3rd, and getting FIRST.
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Old 11-10-2011, 09:05 AM   #52
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Looking Good DP!!
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Old 11-14-2011, 07:13 AM   #53
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Looks like I'll have to do the same thing!


Cheers
Baza
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Couldn't afford a 'GSA', so now it's an 'XSA' "I didn't do it! & whoever said I did, is a liar!"
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Old 02-28-2012, 04:13 PM   #54
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Progress! I decided I really didnt like the way the first part of the pipe curled, so I built a new first cone and re-did it. Lots tighter now.



Still need to clean up some of the weld warts from patching burn throughs, but the hard part is DONE. Also need to weld a couple of hangers on. Its just ziptied roughly in place for now.





It will sit about an inch and half higher than in this pic.

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Old 02-28-2012, 04:44 PM   #55
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Righthand corners could be interesting!
Cheers
Baza
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1981 XS650SH "Tourer" [ For Sale - when / maybe?], 1975 XS650B "Adventure" ['Kenny Krazyhorse'], 1982 XL500R 'Project'
www.aussiegreyghost.smugmug.com
Couldn't afford a 'GSA', so now it's an 'XSA' "I didn't do it! & whoever said I did, is a liar!"
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Old 02-28-2012, 06:20 PM   #56
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Supercool. Love this thread!
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Old 02-29-2012, 01:29 AM   #57
hunter_greyghost
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That's great progress you're making there dorkpunch,
my old beast is still on the project waiting list & stuck in the back of the workshop

Cheers
Baza
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1981 XS650SH "Tourer" [ For Sale - when / maybe?], 1975 XS650B "Adventure" ['Kenny Krazyhorse'], 1982 XL500R 'Project'
www.aussiegreyghost.smugmug.com
Couldn't afford a 'GSA', so now it's an 'XSA' "I didn't do it! & whoever said I did, is a liar!"
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Old 02-29-2012, 09:26 AM   #58
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Great progress dorkpunch!
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Old 03-01-2012, 06:29 PM   #59
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Worked a bit on the kickstand the last couple days. Heated up some tube and smushed the end in a vice to get two flat spots, then drilled a hole. Came up with a rough idea of what I wanted the mounting tab to look like.



Did some measurin and torched the tab, cleaned it up with the grinder and file, and put a hole in it. Made a pin for the tab by turning some rod down a titch and then threading the end.



It'll be welded in from behind to look like this:



and then the kickstand will go over top of it and be held on with a castleated nut.



The whole tab will get welded to the left rear set. I think the hard part is going to be getting the spring in the right place to hold it up and down at the right place. Picked up some hardware and hoping to get it tacked together tomorrow! Along with making some rubber isolation mounts and getting the muffler "finished" and mounted.
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Old 03-01-2012, 07:20 PM   #60
hunter_greyghost
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That's a brilliant design old son, I'll post a photo of one I made for my 'Adventure' XS650 later, [after I take it!]
Cheers
Baza
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1981 XS650SH "Tourer" [ For Sale - when / maybe?], 1975 XS650B "Adventure" ['Kenny Krazyhorse'], 1982 XL500R 'Project'
www.aussiegreyghost.smugmug.com
Couldn't afford a 'GSA', so now it's an 'XSA' "I didn't do it! & whoever said I did, is a liar!"
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