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MCCBoise
03-30-2010, 8:03 AM
Hey guys. New to the forum but I've been a long time member of XLForum.com. Now that I'm just about finished with my XLH build and moving on to my XS650, it's not longer the right place to post about this new project .

I always appreciate a thread with pics showing how everything was done, so that's my goal here is to make it easier on the next guy doing the same thing and hopefully learn from my mistakes.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01656.jpg

I picked up this project from a guy here in Boise who owned a shop here a couple years ago. He got an AR-15 I built and I got the frame, motor, tank, bars, brackets, spacers, headlight, tailights, seats, sissy bar, pipes and some other crap. I try to make everything I can so I probably won't use most of the parts he gave me but it'll be nice to have them there in case I'm feeling lazy.

The frame was manufactured by Maximum Motorcycles Inc out of Ontario Canada. It was made to take a 200 rear but I narrowed the back end to fit a stock harley wheel. Speaking of wheels, I just picked up a set with good rubber for $100.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01662.jpg

Got the rear wheel spaced up and got my chainline straight. Next I made sure that my frame was level

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01665.jpg

Once level, I shimmed the motor to get it to the correct height and then centered it in the frame

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01664.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01663.jpg

Next I cut some 1/4" plate to make the front motor mount. Easy enough with a band saw and drill press. I'm not the greatest welder but I can lay down a decent bead and my Hobart MIG 180 makes it pretty easy on me. I should also mention that whenever I'm making any mounts I always either mock it up with some poster board or really thin plate before I make final cuts to the heavy stuff.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01666.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01667.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01668.jpg

MCCBoise
03-30-2010, 8:05 AM
Now that the front was done I moved on to the rear mount. I quickly bent up a little bracket to hook on my bottle jack to raise and lower the rear of the motor while leaving my mounting holes clear.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01669.jpg

I threw some all thread through the mounting hole and made a paper template of my mounting bracket.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01670.jpg

I know that most guys will just run a cross member between the frame rails and then make two brackets to come up on each side of the mounting holes. I didn't do that for 2 reasons. First, I liked the look of the frame without it and I thought it might make it easier to take the motor in and out.

With the template done, I cut up the plate and added a brace on the back of the bracket to give it some extra horizontal support.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01671.jpg

With those done, I tacked them on, threaded the ends of a piece of 3/8" rod, cut some spacers and it was done.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01672.jpg

Well the lower mounts are done with exception of some finishing welds on the rear. The top mount is easy and I'll snap some pics of that when I tackle it in a couple days.

I bought I vintage 14" over girder that should be here today. Don't know yet if I want to rake out the neck or cut the girder down. I'll mock up and post some pics both ways.

BTW, if any of you know guys in the Boise ID area who want to get involved in a community of amateur builders or just tinkerers, point them to my blog at www.mccboise.blogspot.com. Not many places for normal middle class white guys to go to find others who like building as much as they like riding. That's what I'm trying to start, of course you don't have to be white, that's just a description of me.

xscorex
03-30-2010, 8:10 AM
cant wait to see what this turns out as, In my mind I think its gonna look like ass since the frame is much bigger than the motor, am curious to watch as yoyu tackle the problems as they arise

MCCBoise
03-30-2010, 8:20 AM
cant wait to see what this turns out as, In my mind I think its gonna look like ass since the frame is much bigger than the motor, am curious to watch as yoyu tackle the problems as they arise

Understandable. Width wise I'm good. As for the rest of the space, I'll put a battery behind the motor and an oil tank above the battery that will house all the electronics. I think it will look great. Seems like a lot of good chops looks are ruined by the empty space left when working with an XS650 motor.

Punkskalar
03-30-2010, 9:14 AM
Understandable. Width wise I'm good. As for the rest of the space, I'll put a battery behind the motor and an oil tank above the battery that will house all the electronics. I think it will look great. Seems like a lot of good chops looks are ruined by the empty space left when working with an XS650 motor.

Just don't do the same ol' "fake Oil Bag" to hide your electronics... Something about "Fake" and chopper doesn't seem to work for me :)

nohonestlyitsme
03-30-2010, 9:34 AM
interesting, looks cool

rick667
03-30-2010, 10:07 AM
Very interested in this build man. Keep the updates comin'

MCCBoise
03-30-2010, 10:59 AM
Just don't do the same ol' "fake Oil Bag" to hide your electronics... Something about "Fake" and chopper doesn't seem to work for me :)


I agree. In fact, I think oil tanks are too expensive to get one and chop it up. I was thinking along the lines of an electrical junction box but cutting up an old extinguisher works well too. That's how much of my project goes. Find some garbage and make it work.

MCCBoise
03-31-2010, 8:36 AM
So I got my girder last night (I'll post pics this evening). I'm going to shorten the front end like 14". The problem I have now is that my damn 21" wheel is too wide. I picked up a set of harley wheels from a dude for $100. The front is a dual disc model and is close to 2" too wide for my girder. I'm getting pretty good at selling crap on ebay. I guess the search is on for a skinnier wheel which sucks because I can't cut up the girder until I get that new wheel. Anyone want to trade?

MCCBoise
03-31-2010, 3:46 PM
Here are a few pictures of the girder. After work today I headed over to the local bike salvage yard and traded some odd parts I had for a 21" wheel with a hub brake from some old kawasaki dirt bike. You can see in the pic that I will be cutting quite a bit off the girder. I'll be making axle plates out of 1/4" plate and haven't decided yet if I want to put a MIG bead on it or take it to a local guy to get TIGed. Look at all the biker back in the 60's and 70's who Arc welded everything! I think most people underestimate the strength of good welds. MIG aren't the prettiest but when done right they're plenty strong for the job...who am I kidding? I'm not going to pay somebody to TIG my forks when I can weld them myself!

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01674.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01676.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01677.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01678.jpg

MCCBoise
04-01-2010, 8:01 AM
Made some progress on the front end. After getting the front end on and getting the wheel to the proper height, I marked the legs where I wanted to cut them. (Note, I added an extra 1.5" to the front end which will put the bike slightly off level but give me a tad more clearance as well as compensating for the weight that will be on the forks with a rider and the weight of the motor)

A unique thing with this girder is that the legs are welded together with the crossmember and can't be pulled apart. With that in mind, I welded an axle to my workbench to keep the legs in place. Then I marked them and went at it with the sawzall.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01679.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01681.jpg

Flipped it over and did the same on the other side. After I had both legs cut, I measured them and one side was about 1/8" longer than the other. I hit it with a flap disc to remove most of the material but for fine tuning, I always prefer to work with a file.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01683.jpg

With both sides the same length I got out the torch and bent both front and rear legs in equal distances to keep a nice straight line to the center of the pivot point.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01686.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01688.jpg

I haven't made the axle plates yet but you can see that I'll be using 1/4" plate. Don't know yet if I'm going to just do a standard rounded plate or if I'll get creative.

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01690.jpg

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01689.jpg

philbey
04-01-2010, 11:05 PM
Wow this is looking like a great thread to watch.

That girder is fantastic. And althought thr fram makes that motor look small, I'm keen to see what comes of it all/

calicruiser
04-01-2010, 11:20 PM
Just don't do the same ol' "fake Oil Bag" to hide your electronics... Something about "Fake" and chopper doesn't seem to work for me :)

the "fake" oil bags aren't really "fake". They are just round electric boxes. They take up some emtpy space under the seat just like an oil tank does. I think they are a good solution to the "empty" space everyone seems to hate on most xs chops. IMO some space is a good thing on any chop. just my opinion, not entirely directed towards you punk, cause I dig the hell outta your scoot.

josh

calicruiser
04-01-2010, 11:22 PM
I agree there is a lot of open space with combination motor/frame. Interested in seeing how it looks furthe a long. I definitely dig the stance!

josh

Twinkies
04-01-2010, 11:43 PM
In regards to the open space in front of the motor.. really I dont think it will be an issue once the exhaust is on. It just gives you more options on how you want to run the pipes.
Great start!

GoyaNator
04-02-2010, 7:08 AM
this bike is gonna be sick,,nice work man

shop102
04-02-2010, 11:23 PM
i think im the only guy that LIKES the open space under yer butt. this bike is gonna be BAD. keep up the killer work

wildcard
04-06-2010, 2:41 AM
Ex- cellant! that is the shit! my son in law and i am about to do a similar project. i really like the stance of the bike and you are truly on the right path with design and engineering. dont be afraid of your welding abilities. i have seen dragsters put together with heat and cloths hangers. make sure the metal is clean of paint and chrome , bare metal. then lay a proper bead! that is cool as shit.

Vinny
04-07-2010, 9:03 AM
I dig the open space too. My bike should have a decent amount of space under the seat and I want to make a bag for it. something that clips on and off and looks like a bag. Not an oil tank.

Open space is cool. Thats the whole point of stripping a bike. Definetely digging that front end.

KrOwN
04-07-2010, 9:59 AM
very very nice!! cool build

MCCBoise
04-07-2010, 4:19 PM
Thanks for all the discussion. Helps a lot when building bikes.

I ended up using the original axle mounts from the girder. Here's my issue now, the axle on the dirt bike wheel is 15mm. I took the bearing down to the local bearing shop today and after a ton of research, they told me conclusively that they just don't make bearings in the size I need (I was looking for a bearing with the 5/8" ID. So now I have a 15mm axle and a 5/8" mounting hole on the girder.

Guess I have a couple options.

1. I can cut them off and make new axle plates with a 15mm hole.
2. I can machine down the 15mm axle ends to 1/2" and make a sleeve to fit the 5/8" hole

or...?

What do you guys think? easiest options?

http://i82.photobucket.com/albums/j273/Kellenlogan/XS650/DSC01701.jpg

LawnDart
04-07-2010, 5:13 PM
First off i think the bike is going to look sick when you get it all done and I think it might be easier to cut off and remake axle plates.

jacktorrance
04-26-2010, 7:38 PM
Ditto what LawnDart says...excellent job of documentation by the way!

hotdamn
05-09-2010, 11:31 PM
what about having your local machine shop make brass press in spacers to bush your 5/8 axle opening down to15mm?

don't know if it would work but would definately give it a shot before you go cutting your girder apart...

fuckin tits build by the way.

can't wait to see this shit rollin!!!

theasphalt
02-08-2012, 4:48 PM
This is so rad ass. Can't stand the wait. get it done!!! ;)

GRHebard
02-08-2012, 7:56 PM
this is wild, nice trick for shortening the girder.
as far as the axle issue, turning down the axle a little bit and making a brass sleeve isnt a bad idea if you know anyone with a lathe

cstafford
02-08-2012, 8:05 PM
So did he ever finish it?