My XS650 project...

[04zx6r]

Hey guys, figured I'd throw up a couple pictures of what I'm working on. Yet another long term project, this one won't be done for at least a year or so, but I'm having a blast building it.

Specs:
1978 XS650
2004 zx6r front forks
Chrome spoked wheels front and rear
240 rear tire, 120 front
Clip-on bars
Lot's of other good stuff yet to be bought

So here's the concept, I know there's a lot of people lately that will hate on the large rear tire, but since I was 12 I knew that if I ever built a chopper it'd have to have a 240 on it, so that's what I got, and I love it!
The bike will not have a kickstand, the rear half of the frame and the swingarm I will fabricate myself, it will hinge at the bottom frame-rails, and will have an air cylinder attached. When I park the bike, It'll simply set down flat on the frame, then lift up when I go to leave.
The tank will be a standard sportster tank, but I'm going to build an exocage around it to give it some pop.
I'm running the full twin disc front brake setup from a 2004 zx6r-I had one of those before, and I love being able to stop well.
The clip-on bars look hot, but I just might come up with a newish idea (i'm sure someone has done them before) but they'd be clip-on mini ape hangerss. Could definitely look pretty cool

I'm building my tubing bender right now- should be done in a couple weeks or so, as soon as that's ready, I can finish chopping the rear half of the frame off and building the new rear section.

I know this bike isn't very traditional, but I'm all about expanding new borders and new challenges for myself, and I'm thinking that this project has what I'm looking for, and to be honest, I'm very excited with what it's looking like so far.

I just finished building a supercharger system for my old car from scratch, here's the complete build-up log from that if you'd like to see some of what I've done in the past.
http://forums.neons.org/viewtopic.php?t=254466


Now I'm looking for something new, and I can't wait to get into this further.
Progress will be slow because my wife and I are paying off some debt, and we have a limited allowance, but I'm pretty good at stretching money, as I'm sure many of you are as well, Ebay is my friend

Enough talk, Here's the sweet bike when I got it.
Very hot


took it down to the bare frame quickly, mocked up the new forks


Got my wheels and tires, I LOVE this thing



Time to start chopping!



Now keep in mind all that rear frame section will be gone eventually, this was just a basemark because that's about where I'll be sitting on the finished product.





Think I'll be low enough.

And finally, here's my super sweet MS Paint version of what the frame and bike should look like when done.


Comments and critisisms accepted

[jsdiamond]

That is totally henious!

[do the dew]

Might want to put some more thought in your riding position. Unless you sell this thing to a midget. It looks like you'll need some stretch in that backbone. Nice concept though.

[04zx6r]

Originally Posted by do the dew

Might want to put some more thought in your riding position. Unless you sell this thing to a midget. It looks like you'll need some stretch in that backbone. Nice concept though.

I'm not too worried about it, I've been riding sportbikes for the last 4 years, so I'm used to being cramped

[YoungBlood]

Looks like its going to be a fun build. I like the clip on's... But wondering how the air setup will work. Put a chain tensioner on it? That i guess would be my only worry. Good luck bro and keep the pics and ideas rollin

[04zx6r]

Originally Posted by YoungBlood

Put a chain tensioner on it?

Yeppers, I already have that designed as well, just have to build it, but that's later on down the line.

thanks for the comments so far!

[04zx6r]

Originally posted by 04zx6r
I'm building my tubing bender right now- should be done in a couple weeks or so, as soon as that's ready, I can finish chopping the rear half of the frame off and building the new rear section.

Hah, I make myself laugh- so three months and two welders later, it's finally finished

I finally ponied up and bought a Miller instead of that chinese welder crap. I feel much better now, plus I can do aluminum, but I don't have a plasma cutter anymore, oh well, the trade off was definitely worth it.
Here's a couple shots of the tubing Bender.
I have realized that drilling large holes through thick metal is NOT my calling in life- that has to rank high on my list of crappiest jobs ever.





I built myself a little table to raise the level of the bike to where I could work on it better, and sort of use it as a frame jig. Don't worry it's not fully bolted down or anything, just used this shot as a reference.
This is basically the length the bike will be when done; 7' 4"
So it's pretty lengthy, but again, now that the bender is done, I'll be able to brace the frame, and cut the final part of the rear section off and FINALLY start building the rear frame sections.




Thanks for looking and hopefully I'll have updates a little more regularly now

[Hanoverfiste]

I'll be keeping an eye on this thread!

[iron_dragon58]

Love that home made tube bender. and the project looks like it's going to be a sweet ride when your done, I'll be watching your progress.

[chuckyj95]

what did that pipe bender cost you Im justifing buying one or building one

[04zx6r]

That's a tough question, all told it cost me $400.00 including the die and buying the tools I didn't have.

I say it was worth it, because the pipe bender is automatic and something like the jd2 is a manual bender.

But if you do try to build one yourself, know that you've got all the proper tools to build it. Drilling those holes was the most aweful thing I've ever done. If I were to build another one I would take it to a machine shop to have the holes drilled. and welding that thick of metal pretty much maxed out my tig welder.

It took me forever to get it all together- so I'm happy with it now, but a lot of other people have put them together a lot quicker than I did, so it's all about your determination I guess.

For the time savings for me, I should have just bought a JD2- it's cool sometimes to say that you built it yourself, and I am proud that I finished it and it works right, but it took way too much time away from the real project.

[Vulcan125]

Looks like a professional shop, almost! Excellent work Dude!

[PoppaDLo]

Well I jus found this thread and am dying to see any new pics or progress you have into the bike. No matter what the rest of CC says, I am with you on the fat back tire. I won't do one on my first bike, but my second will be my dream bike (insert big tire on the back)

[04zx6r]

Got in my tubing last week, was able to get a good start on building the frame.

First off I have to say, to anyone thinking about building one of these tubing benders........DO IT! this thing is awesome! it worked extremely well.

Keep in mind that these peices are just rough cut and set into place with painter's tape but you can see the general shape. I should be able to refine this setup a lot in the next week or so.
Until then, here's some pictures to tide you over.

Looks like just a bunch of bent metal



mocked into place





It's going perfectly so far, I'm really excited because what's in my head is coming out through my hands perfectly.
Stay tuned for the next updates!

thanks
Sky

[04zx6r]

So i got some work done this weekend, and should have been able to post some good pictures of that, but about 2:00 on sunday my angle grinder decided to try to cut off my index finger of my left hand.
a trip to the doctor and 6-8 stitches later i should be o.k.


hopefully i'll be able to finish some stuff up this weekend and get you guys some good pics of the progress.

On a side note, my total count of novicane shots is up to 46!

moral of the story, don't be a dumbass when using a grinder.