XS1100 Brat bike build (was I don't keep secrets I got a new(to me) bike)

Discussion in 'Some Assembly Required' started by VxZeroKnots, Jan 14, 2012.

  1. Brainless_1

    Brainless_1 Loose Nut!

    Joined:
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    I found it there.
    #21
  2. VxZeroKnots

    VxZeroKnots Long timer

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    Today I fired up the t-handles and the sawzall

    <a href="https://picasaweb.google.com/lh/photo/h_5ddLVfM39GqxdenAT07w5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-aLTKHqtd6ME/TxpcgMCAdUI/AAAAAAAACTw/TM0gAnjfTak/s640/IMG_0464.JPG" height="427" width="640" /></a>

    No going back now, might as well make the best of it.

    <a href="https://picasaweb.google.com/lh/photo/aodOyWs91SJDBpICY7iGQQ5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-k1PobQRX1zc/Txpcfu3T6xI/AAAAAAAACTs/xHYCvKqM_pU/s640/IMG_0468.JPG" height="427" width="640" /></a>

    Despite many craigslist postings stating the contrary, this bike most certainly has been down... :eek1

    <a href="https://picasaweb.google.com/lh/photo/U8UNdrwzApSVnZUaBM_xZQ5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-KQqtKjWcDTI/TxpclaT3EqI/AAAAAAAACT8/xk-3UpIG5Vw/s640/IMG_0466.JPG" height="427" width="640" /></a>

    Not sure how I'm going to finish this, but here is how it all started.

    <a href="https://picasaweb.google.com/lh/photo/z6_CRGvPt32M_6i1aJn13g5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-Q_8RwFFvRuU/Txpc2bheGBI/AAAAAAAACUE/TYOz-jHK3V4/s640/IMG_0470.JPG" height="427" width="640" /></a>

    Feathering off the gap. Get the welder then...

    <a href="https://picasaweb.google.com/lh/photo/Wh3ojxCpzbPpYlC36_iQjg5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-hC2Blcjf_Ws/TxpeyBNTt2I/AAAAAAAACVA/kc06gq8jP9w/s640/IMG_0471.JPG" height="427" width="640" /></a>

    Mocking up with mini clamps.

    <a href="https://picasaweb.google.com/lh/photo/p3zsYbAjXd_tusXNEelEPg5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-jrseEN1Ftxk/Txpc8-kXPmI/AAAAAAAACUM/C2a_T2g9Owo/s640/IMG_0475.JPG" height="427" width="640" /></a>

    Mucho agujeros

    <a href="https://picasaweb.google.com/lh/photo/9_9z5IGB9GO_qzmVZPsTbQ5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-QDkL0syn10Q/TxpgwG4M_8I/AAAAAAAACVY/Q1xsxOhb4oQ/s640/IMG_0473.JPG" height="427" width="640" /></a>

    No más agujeros en la defensa

    <a href="https://picasaweb.google.com/lh/photo/CL2RvF_8LTXx6BB1l6zCYA5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-Nz6-M_9GSDA/TxpdAde-w9I/AAAAAAAACUU/IvJo6FdZSUw/s640/IMG_0476.JPG" height="640" width="427" /></a>

    Hammers plus beer plus homemade tacos plus more metal and some cuts burns and cursing.

    <a href="https://picasaweb.google.com/lh/photo/c2RcKpFpfTAswd7w1shAkw5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-aK5UBQRRVnk/TxpdMiXaLVI/AAAAAAAACUc/XtW9Fn-tkxc/s640/IMG_0477.JPG" height="427" width="640" /></a>

    Still gotta feather and plate the bottom part of the frame end but I wanted to get the fender lined up with the rear tyre and in place.

    <a href="https://picasaweb.google.com/lh/photo/v_BVtbgVEbr3dE6jxisaKg5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-0Sv1j2v8lDE/TxpdRrCm5ZI/AAAAAAAACUk/5JSrqk3JExU/s640/IMG_0478.JPG" height="640" width="427" /></a>

    Kinda sorta what I'm going for, aside from seat foam, pan and a metric crap ton of rivets it is still missing something.

    Bars probably. tank?

    <a href="https://picasaweb.google.com/lh/photo/DzVPCxvvwJBTHI_0qV4mVg5qprMZxaP1lJVizEby-CQ?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-Bdx9tYhosac/TxpdUz0zsJI/AAAAAAAACUs/qPMyNAX_mjI/s640/IMG_0480.JPG" height="427" width="640" /></a>
    #22
  3. VxZeroKnots

    VxZeroKnots Long timer

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    So in the beginning I wanted a seat with exposed rivets affixing the cover. Having never worked with leather or this technique before I suppose my final result is as good as one could expect. :cry

    In the future i hope to revise the seat using what I know now to produce something a bit more "finished". In the mean time we'll see how this one wears in, and it was such a labor intensive process it is worth sporting for a while, at least it is comfortable. :rofl

    Start with a flat piece of sheet steel, in the future I may utilize alum though that presents its own challenges.

    <a href="https://picasaweb.google.com/lh/photo/JNb_-Gutb7tN1m_e7HnuhYwEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-C0b6mcpSQnc/TxuwtUMd5rI/AAAAAAAACWA/dO_gJKXdjww/s640/IMG_0482.JPG" height="427" width="640" /></a>

    Some hammer, anvil and dolly work gets the beginning shape.

    <a href="https://picasaweb.google.com/lh/photo/3N9knqJws4mxW7uArY4l_YwEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-4_L8FXXaNKI/Txuwsq-6mkI/AAAAAAAACV4/292fIhdW91M/s640/IMG_0484.JPG" height="427" width="640" /></a>

    Now cut of some extra bits.

    <a href="https://picasaweb.google.com/lh/photo/5HyWruEvmPwyccsQw2i7Y4wEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-S5dVJnsnLJ4/Txuwt7qGF8I/AAAAAAAACWI/o9rihsda5bI/s640/IMG_0485.JPG" height="427" width="640" /></a>

    More time shrinking corners and there she sits.

    <a href="https://picasaweb.google.com/lh/photo/08FzYXYeToBfls2XGGJ0VowEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-PngiJHU2bJE/TxuxNKCzl5I/AAAAAAAACWQ/J0nLDK9DmlM/s640/IMG_0486.JPG" height="427" width="640" /></a>

    Drill some holes and install the OEM rubber baby buggy bumpers.

    <a href="https://picasaweb.google.com/lh/photo/5HdobDY1jqxU9ZRSiT1ywYwEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-C4DaVsRnEOo/TxuxPCSFs7I/AAAAAAAACWY/PE7UewtV_Ro/s640/IMG_0487.JPG" height="427" width="640" /></a>

    I didn't smooth this radius as it would be hidden but that would have probably made the end result better as some of the rivets went in crooked.

    <a href="https://picasaweb.google.com/lh/photo/jsxig9zpYlEgM1XM4p6Cq4wEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-_KHrpLdnfnQ/TxuxRuSxo4I/AAAAAAAACWg/DRhBzf5kc8w/s640/IMG_0488.JPG" height="427" width="640" /></a>

    Run up the first line.

    <a href="https://picasaweb.google.com/lh/photo/--Oeq_-XBuhCbEcGRW6UsowEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-uGPw5DbyeyE/TxuxsGdgCAI/AAAAAAAACWo/xOT5qsOFcHo/s640/IMG_0489.JPG" height="640" width="427" /></a>

    Start stretchin er out.

    <a href="https://picasaweb.google.com/lh/photo/cRSrfoGsJnV7-SqMlwHBcYwEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-z8BDJbKRVPQ/TxuxyHYOxcI/AAAAAAAACWw/XzYcKAOmFJM/s640/IMG_0490.JPG" height="427" width="640" /></a>

    First corner is a little rough but they all improved after that.

    <a href="https://picasaweb.google.com/lh/photo/1u0FVoeUV7JMPqoB1VqiO4wEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-23XnBuYNZB0/TxuxyyZqPGI/AAAAAAAACW4/pvPfIc8Ol_4/s640/IMG_0492.JPG" height="427" width="640" /></a>

    Now that doesn't look so bad, i was able to clean up that leading edge quite a lt, look much better now. Note tail light mocked up.

    <a href="https://picasaweb.google.com/lh/photo/rEG61jGAwMdRE_XIbEZC14wEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-lMw6qJMJGzs/TxuyM-ZiM5I/AAAAAAAACXA/-FMHksE1_Dc/s640/IMG_0493.JPG" height="427" width="640" /></a>

    Profile of the tail.

    <a href="https://picasaweb.google.com/lh/photo/RqCKMAatah0cAke4V3j8IowEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-gwlGzxhV0dg/TxuyUZYzSuI/AAAAAAAACXQ/GsHmMp_bDuE/s640/IMG_0498.JPG" height="427" width="640" /></a>

    From the back

    <a href="https://picasaweb.google.com/lh/photo/m1oEKmZjPKFRs-kBeT_oa4wEmLB5AxlskWD_5vO_Ipk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-HVb8-qmY0HU/TxuyTi445BI/AAAAAAAACXI/D1piyKUNdYU/s640/IMG_0500.JPG" height="640" width="427" /></a>

    If anyone has a line on a tank from an XS11 standard, that is the route I'm wanting to go as I like the higher more narrow profile. Barring finding a suitable replacement I guess I could try my hand at fabbing one.
    #23
  4. VxZeroKnots

    VxZeroKnots Long timer

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    After taking a couple week break to deal with other things, namely a long weekend riding dirt bikes in AZ, I decided to clean up the rats nest in between the frame rails.

    <a href="https://picasaweb.google.com/lh/photo/NzF7zOmI-3IfeFXuL0a4fah6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-EqtONiBtBgY/TzDGRQnalZI/AAAAAAAACYs/PZzl8ZQ19ps/s640/IMG_0501.JPG" height="427" width="640" /></a>

    But first to finish the tail light, I wanted to have the wiring hidden since I was going full bore shade tree in the first place it might as well be clever.

    So I had to turn this:

    <a href="https://picasaweb.google.com/lh/photo/n_MglPcjA9qgRKJzjsibP6h6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-5ejjvYsiW0Y/TzDGQDT4-EI/AAAAAAAACYg/ZH2CEAOepK0/s640/IMG_0502.JPG" height="427" width="640" /></a>

    Into this:

    <a href="https://picasaweb.google.com/lh/photo/8u6f171sjCJQtY-UuXXWrqh6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-ZksHlVFaV9A/TzDGQ_D9wxI/AAAAAAAACYo/ADu_jqnUJtU/s640/IMG_0503.JPG" height="427" width="640" /></a>

    Some hacking, tapping, and grinding later and an embarrassing amount of messing with the bulb housing I eventually combined two to get:

    <a href="https://picasaweb.google.com/lh/photo/fiSFFSL9bTHBLv9ytlWKEqh6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-YGjPwVKAhNM/TzDGW2MBEpI/AAAAAAAACY4/b2kdOrhwUgs/s640/IMG_0504.JPG" height="427" width="640" /></a>

    The side that no one will ever see.

    <a href="https://picasaweb.google.com/lh/photo/o3hrZ-bb5MsZInOtGCGPW6h6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-hLO0lPca72I/TzDGXYjGKEI/AAAAAAAACY8/FhfQmq2lKII/s640/IMG_0505.JPG" height="427" width="640" /></a>

    Next I needed a new tool:

    <a href="https://picasaweb.google.com/lh/photo/RiLeR5EDWyp5vnJvt9yX1Kh6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-390otnTetuI/TzDGXy9vsjI/AAAAAAAACZI/RU221H9_wOQ/s640/IMG_0507.JPG" height="427" width="640" /></a>

    So i could make a bulkhead:

    <a href="https://picasaweb.google.com/lh/photo/wTWNbsa_xNrBhFXm8BYf_6h6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-IwiyXtQVn2Q/TzDGfUDocxI/AAAAAAAACZc/P1g3Fd13in8/s640/IMG_0508.JPG" height="427" width="640" /></a>

    Cleaned up the fuse block and got the bulkhead tacked in. I don't want tire spray mucking up my air filter(s?).

    <a href="https://picasaweb.google.com/lh/photo/3zFq_UYGneHgiRwD2QCGxKh6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-9hbEAagXnqg/TzDGdyxy3HI/AAAAAAAACZQ/MHpA_8JYBQk/s640/IMG_0510.JPG" height="427" width="640" /></a>

    Loomed it all up with zip ties and it might all end up living somewhere around here.

    <a href="https://picasaweb.google.com/lh/photo/6Cl2_DJ9dt6hSTI0I9Kei6h6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-SRNjdPB-Fuc/TzDGe18jsxI/AAAAAAAACZY/uDd99nJWlmM/s640/IMG_0512.JPG" height="427" width="640" /></a>

    Overall there is a little less ugly going on down here and it all should hide nicely when I'm ready to burn things in and put the seat back on.

    <a href="https://picasaweb.google.com/lh/photo/xUhUvqfnTxTGawTeZ6QuB6h6SINTbxFqjjY2gJ50dhk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-b9E812jBmK8/TzDGkgqIZtI/AAAAAAAACZo/LSCoZx7GJ9Y/s640/IMG_0514.JPG" height="427" width="640" /></a>

    Any constructive criticism or ideas would be appreciated since all I'm really going off is a bunch of random pictures and builds on the web....

    :cheersmate:
    #24
  5. cross-country

    cross-country .

    Joined:
    Aug 2, 2005
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    Bad. Ass.

    Looks like it's about ready for a quick shot down MX HWY 1 to me! Vamonos!
    #25
  6. C-Stain

    C-Stain Accredited Nincompoop

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    :lurk


    My first bike was an XS750 Standard. I have a very soft spot in my heart for these old XS machines. Keep going - I can't wait to see the results. Subscribed.
    #26
  7. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
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    Durango CO
    Can't be worse than getting a cactus beard. :rofl

    Nice! I like the look of those too! From what little I've actually ridden this thing (3 days of commuting) they seem smooth and have good power.

    So a while ago I built a tunnel for my potentially new gas tank, but didn't take too many photos or anything.

    It did require me to fab my own sheet metal brake as bending 16ga reliably by hand is near impossible with my level of patience.

    [​IMG]

    I mocked up the general shape with paper, then traced it onto the sheet and wound up with this. I'm using a fisheye lens for this sequence so everything is going to look warped, but it is all less than precise in real life too.

    <a href="https://picasaweb.google.com/lh/photo/gJHx_pVgkE21YRtHat6gT49hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-NhehP4SiePQ/T14YUHYWSRI/AAAAAAAACa8/B8twXbkzvbY/s640/IMG_0537.JPG" height="427" width="640" /></a>

    Then using the cutoff wheel on a grinder, which is all I have and one of the worst ways to do this, I cut out the tank sides. I based these off a paper mockup as well, and threw one side in the break

    <a href="https://picasaweb.google.com/lh/photo/MyUi-uBPi_vzRKMs1eeQ649hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-G0MzefeiDLo/T14ZC0dJDUI/AAAAAAAACbk/Jj8NhV_WPWk/s640/IMG_0535.JPG" height="427" width="640" /></a>

    Got everything all bent:

    <a href="https://picasaweb.google.com/lh/photo/gck_t2mVVJZIMMt9kVMlUo9hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-vebA8g5FsCo/T14ZChRFo3I/AAAAAAAACbc/EA4vuLqTg6o/s640/IMG_0538.JPG" height="427" width="640" /></a>

    They match up pretty well, but any imprecision doesn't really matter at this point because everything gets all warped to hell when you shape it.

    <a href="https://picasaweb.google.com/lh/photo/bhjf51lH4Ls_mlbluO0Ruo9hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-fwUM-cvE_ko/T14ZBwpU8cI/AAAAAAAACbU/m69r_GlAqos/s640/IMG_0539.JPG" height="427" width="640" /></a>

    So using an old shitty anvil, and a T dolly I made myself and a few different hammers I was able to turn a piece of sheet metal and two and a half hours of my life into this:

    <a href="https://picasaweb.google.com/lh/photo/A333YSsSxrswo6t8BijzBY9hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-Ew5U6waa9eM/T14ZIAfhaCI/AAAAAAAACbs/qUajsAkkySY/s640/IMG_0540.JPG" height="427" width="640" /></a>

    A while later I had two somewhat matching sides. Not bad for my first go at this, remember, I am shooting with a fisheye so everything looks warped. That being said, the sides are far from perfect.

    <a href="https://picasaweb.google.com/lh/photo/1eb-u2hjp9WHH70vYeA6tY9hfZjCXdv9UDaq-Qe2EL8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-2k2kDvYyI3A/T14ZIp8lW5I/AAAAAAAACb0/_YJwbj015JE/s640/IMG_0541.JPG" height="640" width="427" /></a>
    #27
  8. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
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    Got into the garage on friday and tacked the tank sides up. I also made a paper mock-up for the top portion, still have to finish the one for the front.

    Pulled it out for a proper look.

    <a href="https://picasaweb.google.com/lh/photo/9PKYNONGhpHjlK_fhxF5G44qG2n-uJ1VN307mj_WNy0?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-KctqaOPtyNc/T2VhwF7zw_I/AAAAAAAACcg/ax2EWm8cd08/s640/IMG_0544.JPG" height="427" width="640" /></a>

    It's crazy how easy the metal is distorted, it should be easy enough to massage it "square" in the end.

    <a href="https://picasaweb.google.com/lh/photo/pXSEl3Q3v-sMc5hZ6l2B9o4qG2n-uJ1VN307mj_WNy0?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-0g5p2HvNbZI/T2VhwXJqGXI/AAAAAAAACck/5j_tVaM5RDw/s640/IMG_0548.JPG" height="427" width="640" /></a>

    from the back, it is going to be more narrow at the top and lines up nicely with the seat.

    <a href="https://picasaweb.google.com/lh/photo/NmlRIAfYLlXojU52xmkzKY4qG2n-uJ1VN307mj_WNy0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-VVqx1dkTKdI/T2VhwEEQn2I/AAAAAAAACcc/OJmRSAKGb9A/s640/IMG_0545.JPG" height="640" width="427" /></a>

    What it looks like with a gorilla on it, I ordered a brass thread on gas cap and some drag bars. should be here monday...

    <a href="https://picasaweb.google.com/lh/photo/PWn6ZDgVzGMAxFyg91u3qI4qG2n-uJ1VN307mj_WNy0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-SIvoBYwbPHc/T2VhxGOY_iI/AAAAAAAACc0/WyuiO0Y2gzw/s640/IMG_0549.JPG" height="427" width="640" /></a>
    #28
  9. dentvet

    dentvet Long timer

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    Looks like time well spent. I thought fisher anvils were supposed to be fairly well regarded. If you don't mind, can you measure your front disc thickness and spacing dimensions? I'm considering that front wheel for another bike.
    #29
  10. MODNROD

    MODNROD Decisions, decisions

    Joined:
    Feb 20, 2009
    Oddometer:
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    Midwest, West Oz
    COOL!!!
    Making a "brat bike" or "tracker" or whatever people tag these things nowadays is bound to be fun.
    That XS11 motor is a big old heavy torque lump, a lot like my old Vmax. Also like my Vmax, they tend to jump out of 2nd if they've had a hard life being powershifted (as you do with a shaft-drive tank........*sigh*), easy to fix though.

    PLEASE put 4into4s on the old girl for a real trip.......:deal
    #30
  11. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
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    Durango CO
    4 into 4? Straight pipes might sound pretty good, stockers gotta go but not sure where yet...

    Been a while since an update, but I've been busy.

    Only got one picture, hours of welding, hammering, grinding, testing, rinse wash and repeating and I got this. I now have a honest to goodness gas tank.

    <a href="https://picasaweb.google.com/lh/photo/xx2jYinsuPNnIGZn6Xvns54dGPFuPGk1upHwTzC4m-c?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-meK9Ut2M-pg/T4EMxNpfTbI/AAAAAAAACds/DxyxEyeFN4Q/s640/IMG_0558.JPG" height="640" width="427" /></a>
    #31
  12. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,948
    Location:
    Durango CO
    Good evening inmates...

    Well, I'm officially into the bullshit-blow-my-brains-out stage of the project where I have all the big fun shit out of the way and now it's time to tie up all the loose ends, of which there are a ton.

    First off was to finish off the tank by welding on some mounting tabs.

    <a href="https://picasaweb.google.com/lh/photo/V7LXFzyf5XyuUvdZ23_EWhTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-znUfZL0ARAc/T4pE_M_oKZI/AAAAAAAACgI/H8JbROV9fjw/s640/IMG_0563.JPG" height="427" width="640" /></a>

    <a href="https://picasaweb.google.com/lh/photo/yCVhYqkB_hSocoztwHxI7xTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/--2KZ2ob9evU/T4pE-pjmgII/AAAAAAAACgQ/QHB-wrrwLdg/s640/IMG_0564.JPG" height="427" width="640" /></a>

    Then it was getting the petcocks installed. I opted to use the stock petcocks because I wasn't sure how to deal with all the hoses and fuel pump, or whatever the fuck that thing is, mess and still have the bike run right...

    <a href="https://picasaweb.google.com/lh/photo/FZZbi2x4XyczM7bzl7009xTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-8AjtIQEfnL4/T4pFLQHt_jI/AAAAAAAACgY/wKqkWiTa0VI/s640/IMG_0566.JPG" height="427" width="640" /></a>

    It took a little longer than buying a thread in petcock and bungs and will require me to re-plumb the bastard since I had to move them about 4" forward. I welded on a 2.5" by 1' by 1/8" piece of flat steel to provide a flat mounting surface and to have something substantial to tap for the screws that hold them on and provide a good seal...

    <a href="https://picasaweb.google.com/lh/photo/MPTOzSfo0ISmqmWUPhAN_RTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-0oGGQA3eecU/T4pFNb7hf1I/AAAAAAAACgg/2odYNyuoluA/s640/IMG_0567.JPG" height="427" width="640" /></a>

    Yesterday I got in a new headlight and taillight from Low Brow Customs in Ohio who have quick shipping, good service, and prices I'll pay... After some thought I came up with what I thought was a decent mount, but it still needs some gussets and final welding before installation.

    <a href="https://picasaweb.google.com/lh/photo/MOSqTlKI_StSGK83VF8WWhTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-3WcJ2dBKwtY/T4pE-s-LoRI/AAAAAAAACgA/w1JUCEM4aYU/s640/IMG_0565.JPG" height="427" width="640" /></a>

    The mystery is dead now, this is what the bastard is going to look like, but with some more color, I'm not sure which way I'm going to go color wise, but it'll come out of a rattle can and probably not be very good looking or shiny.

    <a href="https://picasaweb.google.com/lh/photo/0h319fEVuFv7myOvZYBe3hTfC6jZVenYatYsjIrs0Xc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-CakxLgg8e10/T4pFP8ydX1I/AAAAAAAACgo/c8eFXrSt010/s640/IMG_0568.JPG" height="427" width="640" /></a>

    As you can see I still have a good bit of wiring and plumbing to go, as well as order some pods and remount the battery, but I feel like I'm on the home stretch.
    #32
  13. clarkebd

    clarkebd Huh?

    Joined:
    Aug 28, 2006
    Oddometer:
    819
    Location:
    Cary, NC
    Very cool..... keep it updated.
    #33
  14. morena67

    morena67 Adventurer

    Joined:
    Sep 9, 2011
    Oddometer:
    69
    Location:
    Acapulco. Mexico.
    Learning... !!!
    #34
  15. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,948
    Location:
    Durango CO
    well, too much filler and a few empty rattle cans later here we are.

    I couldn't really decide what color so I went with my original inclination of a dark blue.

    It is good from far, but far from good and I'm happy with that. I'll do better next time...

    <a href="https://picasaweb.google.com/lh/photo/696GWA7IeTCa_b-Q2AQ2ZIDq8PhEEA3iOLUq1gor2qU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-GmZfyuEj_Dw/T5jHieEoGcI/AAAAAAAAChU/y2s-0bSdtFs/s640/469627_620743844350_214900620_32277592_1016186065_o.jpg" height="383" width="640" /></a>

    After kludging a temporary battery set up I started clipping and crimping. Multimeters are the fucking shit. I have a suspicion that some previous owner got a little too friendly with the wiring because either the bright beam is always on, or doesn't work, and when I flip the switch the light for the speedo goes out. I tested the leads and they behave as expected so there must be some voltage drop going on somewhere when the light is pulling on it so I'll have to investigate that further... Lectric's aint my specialty, well nothing really is, but especially electrics...

    Moral of the story is that everything behaves the way it did when I took it apart

    <a href="https://picasaweb.google.com/lh/photo/lzN3U0Hn1EQFDn-84x3q24Dq8PhEEA3iOLUq1gor2qU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-vOkwJBr4cRo/T5jHixSWj6I/AAAAAAAAChc/-rauqSRVco0/s640/476718_621413023310_214900620_32280148_577654676_o.jpg" height="383" width="640" /></a>

    Gawd damn I'm getting close to firing this bitch up again and I'm excited!
    #35
  16. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,948
    Location:
    Durango CO
    Well, it's been a while but life and the little things always get in the way. :D

    I don't have much in the way of an update because I've just been tying up all the little crap it takes to finish one of these projects.

    I do have some good news though, it runs!

    <object width="640" height="380" ><param name="allowfullscreen" value="true" /><param name="movie" value="http://www.facebook.com/v/628064089520" /><embed src="http://www.facebook.com/v/628064089520" type="application/x-shockwave-flash" allowfullscreen="true" width="640" height="380"></embed></object>

    Yeah I know, loud pipes and all.... I'll get on that, just wanted to hear it run. I'll get it quiter after everything is buttoned up and it goes down the road some.

    :clap:clap:clap:clap :freaky:freaky:freaky:freaky
    #36
  17. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,948
    Location:
    Durango CO
    Here is a pic I took this afternoon after about a 25 mile shakedown run. It rode well, but certainly has some things still to be buttoned up.

    Not much louder than an XR400, fast, and handles like shit. Hell yes!

    <a href="https://picasaweb.google.com/lh/photo/jS6t1JjjqoGlocMyYj7Fr4Dq8PhEEA3iOLUq1gor2qU?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-Fub_CUY-quo/T7bh9_1O-jI/AAAAAAAACmM/XE35HoqT5w4/s800/IMAG0054.jpg" height="479" width="800" /></a>
    #37
  18. cross-country

    cross-country .

    Joined:
    Aug 2, 2005
    Oddometer:
    1,719
    Location:
    Grand Junction, CO
    Looks to me like you're ready for the Stampede! Just need to install some solid struts and go!
    #38
  19. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,948
    Location:
    Durango CO
    I should probably make some, you know, just to see how it rides.

    Pretty much finished it up on Sunday and wrapped the exhaust still a bunch of little stuff and jetting to dial in. Put 75 miles on it on saturday, so far no performance awards from jonny law so that is good.
    #39
  20. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,927
    Location:
    Arkansas USA
    I have two your bikes little bothers.
    an 850 and 750.... The 850 is a regular ride.
    Funny thing is dad has a 1500 Intruder in the shop too, he would rather ride my 850 it handles better and is easier to ride. :D
    I have a standard gas tank for the 850/750 I'm sure the 1100 is the same.
    But it doesn't fit well in the Special frames. They are entirely different.
    [​IMG]

    Not sure they ever used the Hitachi carbs on the 1100, but if they did be prepared to trash them if they give problems, parts are nearly impossible to find.
    One more thing, they two lines on the petcock one is actually vacuum cut off so when you shot the bike off, it stops the gas flow.
    These bikes are getting old enough the diaphrams in the petcocks are going bad it lets it leak gas into the vacuum port on the manifold.
    If you develop this issue MikesXS sells a regular petcock with on/off/reserve as these should have had.

    Nice work.
    #40