View Full Version : 1996 VLX Project

02-27-2014, 8:40 AM
Hey guys,

I've been watching the builds on this board for an age now, and signed up fairly recently so I thought I'd post up what I'm doing with my current project.

I'm building my second dual carb VLX (my first back in England) and plan on hard tailin' and bobbing it. First thing's first, some pics of when I picked it up:


The ride home from picking it up was dodgy as hell as it wasn't running anywhere near as well as it should be, and I'm sure a granny could have walked past me at the speed I was having to accelerate at without killing the engine. So first thing I had to do was to strip the carbs out and rebuild them, and it runs a lot better now but I think it's weak on the spark side, so need to get a set of iridium plugs or something soon... but for now it goes just fine.

I got to work with cosmetics initially, changed the tear drop mirrors, changed the levers from flame back to powder coated stock levers, removed the chain guard, etc etc. I also replaced the turn signals with some sleeker black LED ones, but they are now hyperflashing so need to install a resistor (soon). That left it looking like a nice clean start of a project:


I've also started to clean up the bars a bit by relocating the kill/starter switches to the neck, but I'm just waiting on the final push button to be delivered:


Removed the EPA crap to make space for a battery cage so I can drop the battery:


Now there's a nice big gap for the battery cage!


This weekend should be ditching the fuel pump and relay and removing the coolant overflow tank. I've also got keystone bars, single cable throttle assy, new grips, etc on their way.

Next week, should be building my exhaust hopefully if I get the time, and in the coming month, chopping the back and hardtailing it with a strut to start with. If I like how it feels, then I'll hardtail the frame itself.

Also plan on getting a fender and bits from lowbrow customs, rejet, get velocity stacks and a dished sporty tank from TJBC (along with some other bits). I'm also building another custom saddle from scratch for this bike, and maybe a nice swingarm saddle bag with some tooling... watch this space!

This is going to end up blue metallic flake/black/white mixup... should be interesting :D

A quick one of my last build in the uk:


Anyway, good to finally start to post the project on here! I'll keep you updated on the choppin' progress :)


02-27-2014, 9:39 AM
List of sh*t to be done:


03-03-2014, 6:09 PM
This should give an idea as to the obnoxious blue flake that some major parts on the bike will be...


Candy blue flake for the fender, wheels and tank. Similar to this:

Single pull throttle assembly arrived today too.

Bars arriving tomorrow. Chopping, building and welding starts on Wednesday.

03-03-2014, 6:30 PM
I like the color already

Sent from my Huawei-U8665 using Tapatalk 2

03-04-2014, 3:31 PM
Ok, so an update...

Finally got the bars and everything on today. Had to drill out and re-tap the single cable throttle assembly:


Then put the keystone bars on with the new throttle assembly, and get started on the wiring for relocating the push button starter and the kill switch:


Then finally, a few hours later I emerged with a bike that felt completely different:


Next stage is to chop...

03-06-2014, 9:39 AM
Ok, last night the back end was chopped off, seat plate tig welded, chopped off the passenger foot pegs and chopped them up and welded parts of them under the seat pan for turn signals.


03-06-2014, 11:15 AM
Some more pics:


03-06-2014, 6:08 PM
As she sits now... At least it's rideable. Got lots to tidy up with covering the electrics etc. then it's more fab work with the battery cage, hardtail, fender, etc and paint.


03-10-2014, 5:27 PM
Another quick update...

Put on my new tail light today:
Was initially confused by the wiring, but then realised it grounded through the mount! Doh!

Re-routed h/light and horn switches:

This was a complete pita, because I measured incorrectly and the horn switch ended up pushing on the rad cap! A quick bit of jiggery pokery and all was sorted though.

Then I thought I'd have a go at working with the existing side panels. Being a pre-2001 it has the long side panels with no top coverage so the electrics poke out. I wanted to make something that fitted around the turn signals/indicators and covered the electrics on top. Still a way to go yet, but here are some pics as I know how you all love 'em!


Now I have a piece of fiberglass stuck in my nose and it itches like f*ck!

03-13-2014, 11:11 AM
Ok so it's moving forward again... I need to get the side covers finished before I can drill and seat the turn signal switch... So without that, the bike won't be moving. Making progress though...

Thanks to some helpful advice from TJ Stiles at TJ Brutal Customs, I decided to remove the triangular resevoir to make more room for electrickery tucking away so the neck panels would fit snuggly.

I'll also be turning my petcock forward and removing the fuel pump, switching to gravity feed.

I then left about a foot of tubing from the rear cylinder to vent to the atmosphere, and needed to plug the feed on the stock air intake as a result. I took the plug from the resevoir and chopped some of the tubing to make a new plug.

Then I started on the right side panel by mocking up with wire frame' same as the left side:
Then laid down several layers of fiberglass strips, waited for it to cure, added some bondo and now we are finally getting there

Still need to add some fine tuning to the shaping of the side panels, but I'll probably be able to get them painted and on in time for the weekend - just hope this weather holds up so I can go riding!

Today, I'll be finishing of the electrics and putting the front neck covers back on with all of their switches, and extending the wiring for the turn signals to the side cover area.

03-21-2014, 8:02 AM
How did you get on turning you peacock and with the gravity feed, I've got my shadow all torn down at the moment and am wanting to ditch as much as I can,

03-24-2014, 5:07 PM
The gravity feed works just fine for now! I plan on putting a sporty tank on it with a sight tube though - don't wanna get caught short :-)

There hasn't been any change really, all the fuel is flowing as it should.