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  #1 (permalink)  
Old 05-06-2010, 01:25 PM
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My '00 Roadstar Project

Last month I bought a 2000 Roadstar just as a beater bike to ride around while I was finishing up another bike I was building. I already have an '03 that I keep out in AZ because I go out there a few times a year to ride, and I love it. The '00 was a great deal and I couldn't pass it up, only problem was, it was pink! So here are a few pics of my progress so far...

Here is the bike as I got it, a very faded Magenta or something. All I know is it looked pink!





First thing I did was start stripping off all the big clunky stuff that Yamaha hangs all over these things.



Here is a shot of my brother cruising down the highway after I cleaned it up a litte, but it still has a long way to go!



Next I decided to make up a nice set of 1.25" apes. For some reason I don't have alot of pics of this process, but basically I started with some scrap tubing that I bent around the counterweight on one of my forklifts at work...



Tubing cut and notched, ready for welding..

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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 01:26 PM
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Trial fitting them



Fairing in the welds and primed, I will paint the bars flat black when I do the tins



I got a good deal on a set of Harley/DNA fat spoke wheels, so I had to do some adapting. The new wheels are 18" x 3.5" in the front and I went to a 5.5"/180 tire in the rear.



I made these adapters to fit the meteric front axle to the Harley wheel. The idea came from a guy on this list The rear was just a simple bearing swap, and I had to ream out the center spacer:







The pulley was a bit of a PIA. I got a Harley pulley off ebay, but I don't know what I was thinking because I bought the wrong size center hole. It wasn't a big deal anyway because I needed to make a hub spacer to get the belt clearance I needed. I had to bore the center hole on the pulley:



Then make the hub spacer to center on the pulley and the wheel:



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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 01:27 PM
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It's hard to see in the pic but I made this little centering spacer so I could set the pulley on the spacer, drop the little spacer in each bolt hole, and it would center the punch in the hole to mark them.



Finished, had to move the pulley outbooard about 7/8" to center the wheel and get belt clearance.



I bought a rear brake adapter from Looneys so I could use the Yamaha caliper on the Harley rotor. It's a little crude but does the job really well. When I get some time I'll switch to a chrome Harley caliper, axle mount it hanging straight down, and run a HIEM link to the Yamaha frame mount, but that can wait.

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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 01:52 PM
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Next was fitting up the rear fender, always a PIA. I got a "desperado" 9" fender from the Custom Chrome catalog. I started by lowering the bike by flipping the suspension dogbone and cutting some off the subframe mounts. I also cut the forward crossbrace and spread the subframe with a bottle jack to get clearance for the rear tire.



From the start it didn't fit all that well but with some cutting up front I got it to sit pretty nicely.



Next step was to fill those big ugly gaps up front between the fender and the frame. At first I tried making panels to fit in there, but in the end decided to just weld a skirt around the whole fender, extending it and starting from scratch fitting it. First I made the skirt by bending it over some galvanized pipe I had laying around. It was easier to make it in two halves than trying to get the bends in exactly the same place on both sides.











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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 01:53 PM
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I made a circle template to shape the fender to match the wheel. Cutting is done with a jigsaw and a metal blade.



Once fit, I used some styrofoam blocks on top of the tire to support it while I located all the mounting holes.



Pretty much done, just gotta fill the holes in the top around the mount, and make the mud guard underneath.





So this is where I am as of today. This weekend I'll bang out the gas tank extension, and next week is making a custom seat. Should be ready to paint by next weekend!
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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 01:57 PM
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Beautiful, precise work. Well done. I am looking forward to seeing more.
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Old 05-06-2010, 02:43 PM
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Good job amigo!!
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Old 05-06-2010, 03:48 PM
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Here is the rear fender, mostly done. I'm going to make a new mud gaurd underneath that fits better and covers more of the tire, to better match the fender. I'm pretty happy with the way it fits. On the kickstand it's not perfect, but when you sit on it everything lines up nicely.



Not 100% happy with this side, but not too much I can do since the belt runs under the fender here, and I need to leave enough room for clearance.



WCC "roller" front fender, not mounted yet, but this is how it will sit.





Here is a pic a friend took of my goofy ass extending wires. I wear safety glasses now for the simplest of tasks. A few weeks ago a carbide cutting bit shattered and nearly blinded me, actually put a hole in my eyeball. I always wear glasses now. The helmet is a goof, that's actually a large DOT but I have no idea how even a small head could fit under there!

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Moe

330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-06-2010, 06:41 PM
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Lookin good Moe !!
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Old 05-09-2010, 01:51 AM
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Did you lose any vision in the damaged eye?
Sounds horrible.

Now I wear a full face shield not just goggles. Actually more comfortable and does not fog up.
I have had safety glasses on and got hit in the face.
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Old 05-09-2010, 10:27 AM
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No, it hit me right where the colored part meets the white part. It was pretty scary because my eyeball was actually bleeding. At first I kept working until I realized all the watering wasnt tears it was blood! Anyway, 2 hospital visits, a dr visit, and a catscan later they determined there was no metal in my eye and I was good to go. Bottom line is that my copays alone were about $300 so that right there is a good reason to wear goggles! First hospital I went to made me wait 2.5 hrs for treatment, so the Dr could come out and tell me "I'm not an eye Dr, you need to goto Wills Eye Center in Philly". Then they sent a bill to my insurance co for $500 for "triage", of which I was responsible for $100. What a bunch of bullshit.
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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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Old 05-10-2010, 03:40 PM
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Thats not the first time ive heard of doctors doing that crap.
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Old 05-10-2010, 04:55 PM
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That setup looks killer. Great work
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Old 05-10-2010, 07:34 PM
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Although not the biggest fan of the tail dragger style fenders I must give you kudos for the effort, craftsmanship & staying on task with you project.

Nice job so far.

PACO
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Old 05-13-2010, 06:28 AM
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WCC front fender needed to be trimmed a little shorter because I put it so close to the tire



Tank extension glued in place. I used this shit called "Maxim" panel adhesive. It comes 2 parts in one caulk tube. I bought a cheap caulk gun because my good one walked away, and instantly detroyed it trying to pump this crap through their special mixing tip. I ripped off the tip and just pumped it out and mixed by hand. Stuff reminds me of a product called "pro-seal" that we used to use to seal aircraft gas tanks. Even smells the same, really messy stuff but super tenacious once dry. After trying 10 different ways to clamp the extension, these $2 clips I had laying around worked perfect.









Here's a shot with the extension in place, really helps the lines:



Bondo and primed





Rear fender, finally ready for paint:



Here is the leather I got on ebay for the seat, love the color:

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330 Monoshock Build
00 Roadstar Project Bike

Cherry Hill, NJ
Fountain Hills, AZ
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