XR400 Four - Skunkworks Special

Discussion in 'Some Assembly Required' started by Pezz_gs, Aug 19, 2009.

  1. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    My Good wife finally made me buy a bike lift, it has been my Christmas present for the last few years, but as January is a quite month and things came up and I spent the $$$ on Bills. So last year she squirreled away a small amount of cash out each week and hid it away and for my birthday with some strict instructions to BUY THE LIFT!!!:deal

    Thanks my Love:happay

    [​IMG][​IMG][​IMG]


    Well I have been fettling away and have made a number of new additions.

    So far I have mounted a rear rack, fitted up the oil cooler (photo to follow) :evil:rofl

    Rebuilt the Fuel Tap, mounted the coil Brackets . . . .

    Anyays the good news today is I have, with the help of Ray Tollhurst out at Camden Airport, made a new single seat base. Thanks so much Ray!!! Legend :thumb

    I have always built this bike so it could be returned to a stock CB400/4 when it was finished. I didnt want to destroy a perfectly good steel seat base I hade to make a new one.

    By fitting a rack on the back from an old Suzuki Ag bike, meant the seat had to be shortened. I could have gone into the process of making a mould but as I just need a simple cope and the steel base was pretty thin I just overlayed the fibreglass over the top.

    So here goes a simple description of the process.

    I had to remove all the glue, foam etc from the old base then tape any holes so the resin wouldnt run through.

    [​IMG]

    Next we had to make a fence for across the back of the seat and fill all the holes with plasticine so they wouldnt fill with resin. The polish the whole area with mould release wax

    [​IMG]

    Next was the PVA mould release, which is like liquid glad wrap.

    [​IMG]

    Now we have a very nice shiny poliched and PVA'd seat to lay the fibreglass resin on.

    [​IMG]

    Laying up the glass matt, 2 layers of 0.5mm and 2 layers of 1.0mm.

    [​IMG]

    Rolling to get the air out.

    [​IMG]

    While it is still a little damp, trim around the part with a stanley knife ready to come off the seat base

    [​IMG]

    lifted off quite easily, and I can see all the locations for the rubber grommets and seat hinge and seat catch to be drilled and bolted on.

    [​IMG]

    Seat sitting on the bike. really happy with it so now, fit up the spacers and hardware, then off to the trimmers.

    [​IMG]
  2. Johnny5jz

    Johnny5jz Adventurer

    Joined:
    Sep 2, 2010
    Oddometer:
    44
    Location:
    Minneapolis
    I like your seat approach. I am working on a similar one right now and glad to see it worked out for your. It gives me a little more confidence to jump into it myself. Great project.
  3. Jacl-Kampuchea

    Jacl-Kampuchea Booze Merchant

    Joined:
    Sep 27, 2010
    Oddometer:
    784
    Location:
    I see Drunk People.
    I never realised you guys are kinda famous until I wandered into an Aussie owned bar here in Cambodia, picked up some bike mags and saw you writing about hopefully having this bike finished in time for the next scrapheap rally:deal

    Anyhow, nice work.
  4. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Thank you

    Its very close now, just need to fit a new chain and connect the oil lines

    Should be done by next weekend :evil
  5. anonny

    anonny What could go wrong?

    Joined:
    Mar 20, 2007
    Oddometer:
    5,772
    Location:
    Beautiful Revelstoke BC
    That was very thoughtful of your wife.
  6. Pez

    Pez b00b

    Joined:
    May 12, 2011
    Oddometer:
    628
    Location:
    Wake Village Tejas
    Amazing bike and awesome work Pez with an extra Z! :clap
  7. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Well the seat is away getting recovered!! Unsure what colour it will come back as the fellow is doing it for nix, and has suggested it might be a bit out there???

    Thought I would show the hardware installed in the Fibreglass seat base. As the imprint off the steel base is on the fibreglass made it easy work.

    [​IMG]

    [​IMG]

    Okay, in keeping with the theme of this bike, form over function, I have done something I wouldnt normally do, Honest!!! :deal

    Mounted the oil cooler on the side of the steel fuel tank. The bolts are spot welded and silver soldered to ensure a good hold. I then made brackets that have the leading edge out further the scoop in the air. The cooler has four rubber mounts to absorb the vibrations.

    [​IMG]

    [​IMG]

    Flame away :norton
  8. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,158
    Location:
    Kiwiland
    Have you also decided to not fall off on the left?
  9. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Thats my good side Nordie :evil

    But the crash bars and Handle bars protrude further than the oil cooler. I Hope :huh
  10. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,158
    Location:
    Kiwiland
    What could possibly go wrong :rofl
  11. radbrad511

    radbrad511 Been here awhile

    Joined:
    Mar 22, 2011
    Oddometer:
    298
    Location:
    San Clemente
    Dudes-
    Totally inspired by Aussies and Kiwis who turn trash into ART. So much so that yesterday I broke out my 1977 C&J framed TT500 that has sat for 25 years. For sure an easier job than what you guys tackle but, my plan is to re-create it as a street legal TT/SuperMoto/Fireroad shredder. Out in the workshop till past midnite stripping it down and cleaning. Today scored a 1991 Kawasaki USD fork that will bolt up with a couple of machined spacers, FREE! Bike still has compression but, thinking I will do a top end freshen up. Will post photos when it is rolling again! Thanks for the push!!!:clap
  12. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,380
    Location:
    Sunshine coast qld
    Looks great Pezz, it's deffinetly in the spirit of scrap heap
  13. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Well the seat was delivered back, after a 10 hour ride from Queensland. I reckon Shane just wanted to see the look on my face. :huh

    I got this pic of the seat with the foam added

    [​IMG]

    thinking this will be nice.

    Well he sent through a few phone pics and I began to become a little concerned!!!

    then he arrived with this :deal

    [​IMG]

    Close up to show some detail :norton

    [​IMG]

    Pilot Air Compressors had a stand at the Hare & Forbes 3 day sale and so we decided to add my XR460/4 to the display. Got a bit of interest too!!!

    [​IMG]

    Actually, I reckon it suits it, although not really convinced about the quilting :gyro
  14. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,158
    Location:
    Kiwiland
    I can't say stylish, but I will say it suits...
  15. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,380
    Location:
    Sunshine coast qld
    I agree with nordie.

    Must have been hard walkng out of that sale without owning lots of shiny new tools.
    I've been thinking about buying one of there mills
  16. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Well it has been a busy week, and as Thrusday's departure approaches there are few things to tidy up.

    I was on the Pilot Air Compressors stand at the Burson Auto Parts Trade show Thursday night. We had a great night and they had their pit girls walking around shaking everyone down for donations!! Will count it tomorrow but seems they did well!! Thanks Bursons and Pilot Air!!!

    [​IMG]

    [​IMG]

    I tried to start it yesterday and no joy, sounded like no fuel and being a bit gummy with old fuel I decided to pull the carbies out for a clean. Its getting easier everytime. :wink:

    [​IMG]

    Grace was quick to point out a clamp that needed tightening. My new Apprentice :)

    [​IMG]

    I took it out for a longer ride today and it starts and runs well. I have gone for 75 to 85 main jets as 80's didnt come in the jet kit I was put onto.

    With the mixture out 1-3/4 turns it was killing the flame, I have backed it off to 1 turn out and it still gets a bit fluffy down low once it warms up. Will try 3/4 turn tomorrow.

    With the lowered pegs it is just about perfect for me and I finally rigged up a left hand rear brake, that works. Very handy as the disc is a bit ordinary.

    There has been a bit of overflow from No2 & 3 carbies but a tap with a screwdriver seems to get the seats to settle.

    It is such a great bike to ride, light and neutral and cant wait for the 5 day Scrapheap Adventure Ride over Easter

    Looking forward to posting a successful ride report once we get home.
  17. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    I am writing a report but after much leakage of fuel from all 4 crabies, often taking turns, the old girl made to Scrapheap 3 with no real problems at all.

    [​IMG]

    Will have some Video hopefully soon too!
  18. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,380
    Location:
    Sunshine coast qld
    congratualations on the bike and the scrap heap ride.

    Whats next?

    for that frame you where telling me about I reckon a twin cylinder two stroke rotax would go good.

    If you get one out of a sled you could keep the cvt
  19. PhiSig1071

    PhiSig1071 What's ******width?

    Joined:
    Apr 9, 2008
    Oddometer:
    2,573
    Location:
    Tucson, AZ
    I like the kickstand spring.
  20. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    It worked well :evil

    Lost the spring and rode about 10k's, holding it up with my foot, to get into Oberon NSW and bought a 60cm Ocky strap.

    It was an auto retract setup and worked perfectly.