View Full Version : Bigsky Beer Budget Build. Vulcan 800 Classic

03-15-2016, 10:19 PM
So i have had this bike since my senior year in highschool. Rode it all over the countryside and even in Germany. After years of owning this bike I have decided to try my hand at maki g some changes. I figured I might as well make a thread to keep track of my progress.

03-15-2016, 10:22 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0064.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0064.jpg.html)
Here is a picture of the bike from 13 years ago when my wife and I rode it away from our justice of the peace wedding.

03-15-2016, 10:26 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0065.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0065.jpg.html)
Here is a more recent picture of where I am beginning.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0068.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0068.jpg.html)

03-15-2016, 10:31 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0069.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0069.jpg.html)

Start stripping it down.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0070.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0070.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0071.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0071.jpg.html)

03-15-2016, 10:34 PM
So here is a start to my seat panhttp://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0080.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0080.jpg.html)

03-15-2016, 10:38 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0115.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0115.jpg.html)

Heres the pan on the bike. After doing a 95 mph test drive i realized that the seat was not the right shape. I had this feeling like i was going to slide right off the back.

03-15-2016, 10:44 PM
Made a legalish way to hold the license plate and threw on an L.E.D tail light that i got from amazon, i will eventually relocated the tail light when I get a rear fender and sissy bar setup. But for right now I cant resist riding. Infact the weather right now is amazing for march in Montana.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0126.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0126.jpg.html)

03-15-2016, 10:48 PM
My bro ordered two sets of bars for his build so he threw me the set he decided not to use. Couldn't turn down that offer.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0131.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0131.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0132.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0132.jpg.html)

03-15-2016, 10:53 PM
In the process of swapping bars I broke my factory throttle tube. So after realizing that a new one from the stealership was $50 I got my ass on ebay and bought a used set of grips with a throttle tube for $10 cuz I am cheap. And finsied getting everything buttoned up
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0133.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0133.jpg.html)

03-15-2016, 10:57 PM
Really starting do dig the way things are going.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0134.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0134.jpg.html)

And since my bud has his bike in my garage and I have been burning the midnight oil on it as well better throw in a shot of it as well.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0140.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0140.jpg.html)

03-15-2016, 11:04 PM
I took the stock front fender and hacked it with a cutoff wheel and have basically scratched my head for a week deciding what I am gonna go with it. Because it is plastic my mounting options are getting creative. I will be building a sissy bar and fenter strut that will be capable of strapping a bag to for some extended trips this summer.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0141.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0141.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0142.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0142.jpg.html)

03-16-2016, 11:54 AM
looks great!

03-20-2016, 5:10 PM
Picked up some 1/2" square stock today when we went to town. Planning to try building a sissybar fender strut this week when o get some free time.

Does anyone have some advice for putting a twist in square stock? Things to keep everything even.

03-20-2016, 6:12 PM
Heat up as much as you want twisted (no more than about 10") with a torch. Get it to a dull orange, even along the length. Clamp one side in a vice, put a cresent wrench on the other end, and twist till it looks good. Usually 3 turns works well.

03-20-2016, 6:16 PM
Aprreciate the help.

04-06-2016, 5:54 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0162.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0162.jpg.html)

Well progress has been slow but there has been progress. I got a good start on my front seat mount.

04-06-2016, 5:57 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0169.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0169.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0171.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0171.jpg.html)

04-06-2016, 9:35 PM
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0174.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0174.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0174.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0174.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0173.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0173.jpg.html)


04-07-2016, 6:33 AM
Your welds look waaay better than mine. Like the seat setup and where this is heading. Good job man it looks sick!

04-07-2016, 10:49 AM
Thanks man. I am headed for a daily rider but something I can strap a bag to and do a 4dayer trip on. Seat will get cushion and covered with leather as soon as I am totally satisfied with the shape and seating position.

04-07-2016, 11:28 AM
Why put a hinge on the seat? Are you planning to hardtail it, or leave the monoshock? Seems redundant, and imo ugly, to have the springs and space between the frame and the seat pan if you don't need to.

04-07-2016, 6:42 PM
Not gonna hard tail it. And I am not using springs. The seat it solid mounted in the rear. I have some rubber bushings to isolate vibration, the hinge is just mainly an easy way to mount the front of the seat. I originally bolted it in the front but it was a pain in the ass to get off. So now if I ever have to get to the battery I just have 2 nuts to take off and the seat flips up. After riding today for a little comfort test I realized that the seat needs a nice slow concave shape throughout the entire length of the seat which will take care of the feel and the look of this thing before it gets covered. Thanks for your opinion.

04-08-2016, 6:06 PM
Well i cant leave stuff alone. So I bent the seat pan some more and added some clevis pins for ease of removal. Now the seat sits alot lower and feels alot better. Any thoughts on thishttp://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0179.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0179.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0178.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0178.jpg.html)

04-09-2016, 6:05 AM
Well I cant leave stuff alone. So I bent the seat pan some more and added some clevis pins for ease of removal. Now the seat sits alot lower and feels alot better. Any thoughts on this.

Go find yourself a solid stump, or a piece of un-split firewood from the trunk. It should be around 12" in diameter. Use a sander disc on a drill to dish out one end of the stump to the amount of dish that you want in your seat pan. Now take your pan and go to town on it. Dish it out nicely where the back of your ass rests, and from the other side, dish it from the opposite side, toward the front where it comes between your legs. This configuration will look more old school and really cup your ass, which will be quite comfortable. It will still look sleek and minimal, and you can tell everyone that you beat it out with a hammer yourself.

I also agree with others, that since you already have a good rigid-looking suspension, that you should eliminate the moving parts and make solid bolt-on connections to the frame. It will look better, and you'll have a better rider-to-bike connection.

Just my two pennies. This build has got me thinking that I may want to abandon some of the shit projects I have going on now and get me a Vulcan!

04-18-2016, 9:01 PM
Thanks higgy, I made some progress. There arent any moving parts. It is coming together and I will post pics along the way. I primed and painted the pan and got the padding on ad shaped. Now i just have to get the leather over it and then it's on to the fenderhttp://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0207.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0207.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0206.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0206.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0205.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0205.jpg.html)

04-19-2016, 2:29 AM
Imo the seat looks good now. Doesn't have that stock lazyboy recliner look. I understand the hinge too. I've built a bike before that the seat had to come completely off to do any kind of battery work. Total pain in the nads.

04-22-2016, 5:00 AM
I dig what you did with the rear fender. These bikes have such am interesting look being mono-shock that it makes it look hard tailed, to me at least!

04-22-2016, 7:08 AM
Looks Great!

04-22-2016, 7:18 PM
Thanks for the kind words guys. I got some more done.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0211.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0211.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0212.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0212.jpg.html)

04-26-2016, 8:25 AM
Ok I am at a standstill on this right now. I started making a few other leather projects to practice the leather dying on before I tried this and ran into a few snags.

I was making a bracelet and a wallet and when i died them using fieblings medium brown and dark brown leather dye they both became extremely dark. Almost black. I let them both dry overnight and they did not get any lighter and they also became very stiff. I tried applying neatsfoot oil today and it softened them up a little but the bracelet cracked when bent. Almost like beef jerky, lol.

Does anyone have som suggestions on an easy to use leather dye thats not going to destroy my seat. Also a good run down on the process you use to dye and finish your leather work???
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0222.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0222.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0217.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0217.jpg.html)

04-26-2016, 9:47 AM
Everything just came out black and crispy instead of brown. Same texture as beef jerky.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0223.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0223.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0225.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0225.jpg.html)

05-03-2016, 2:18 PM
Well I went ahead and sewed my seat by hand and it turned ouy great. Should be able to get the leather dyed and coated this week and then its time for some riding.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0239.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0239.jpg.html)

05-03-2016, 8:03 PM
Your some kind of handy man mate. Looking over your other stuff, although I can appreciate the concern of not hard mounting your seat, as long as your brackets are sturdy and you trust em fucking, I think it's great and I don't think it looks bad at all. No one is going to stare at the seat mount when the rest of the machine looks that good.

05-04-2016, 8:07 AM
Warmullet, thanks man.

I dyed the seat this morning before work, now its time to let it dry for a day or two and then finish coat. Its getting there.

The weather has been so nice I want this seat done so i can get some riding in.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0244.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0244.jpg.html)

05-05-2016, 7:25 AM
Ok seat dried for the las 24 hours, coated it with a protective finish this morning.

I am really happy with how this turned out.

I will butnish my edges tonight and thats all she wrote. Seat will be goi g back on the bike.

Next up is my sissy bar.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0246.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0246.jpg.html)

05-06-2016, 9:34 AM
Seats on!! Rrady to get some riding in this weekend!!!!!! Woooooooo
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0252.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0252.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0254.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0254.jpg.html)

05-06-2016, 11:46 AM
Seats on!! Rrady to get some riding in this weekend!!!!!! Woooooooo
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0252.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0252.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0254.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0254.jpg.html)

So I can send you my seat idea with a check or money order and you'll have it ready for me in, let's say a week?

05-08-2016, 9:15 AM
So I can send you my seat idea with a check or money order and you'll have it ready for me in, let's say a week?

Warmullet. I definitely could. I think the time frame would be closer to two weeks because there is quite a bit of drying time involved. I really learned alot doing this project.

05-10-2016, 8:58 AM
No major updates, washed the bike on sunday and went for a nice ride.

I put a gallon of 100LL AVGAS in the tank and then topped it of with some pumpgas. I rode about 60 miles on some twisty back roads. All in all everything is great. Not to impressed with the avgas, makes the bike run lean. So I think I will just stick with pump gas........ It just wouldn't be practical to rejet richer just to run that stuff.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0255.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0255.jpg.html)

05-10-2016, 1:36 PM
i think your lil makeover came out pretty cool .
good job man :cheersmate:


07-12-2016, 7:33 AM
Well life has been busy lately, I have managed to make a little progress lately though.

Debadged the tank and put the factory rear fender back on and started on my sissy bar finally.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0386.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0386.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0412.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0412.jpg.html)

07-12-2016, 8:52 PM
Got the bends done on the sissy. Turned out great. But i am trying to decide if i should put some reinforcemet bars on it. It would give me somewhere to strap a bag to and add some strength.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0417.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0417.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0415.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0415.jpg.html)

07-22-2016, 10:19 AM
Well i got the sissy bar done and had to test it out before paint. I wanted to make sure the crossbars were in the right spot before i call it done. It held up great fully loaded and she got about 200 street miles and about 40 miles of rough dirt roads. Got some moto camping out of the dealhttp://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0433.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0433.jpg.html)
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0431.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0431.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0425.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0425.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0423_1.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0423_1.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0427.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0427.jpg.html)

I am sort of undecided on wether or not to put some twists in this or not.

I am also undecided on wether or not to powder coat, spray paint, or dipit. The color will be black.

I was thinking dipit would be cool because it is fairly durable but if I decide I don't like it I could just peel it off.

Any thoughts on either idea?

08-22-2016, 6:32 AM
Ok, had some time over the weekend to start mounting my new fender. Once I started measuring a few things I figured out the spot where i will be mounting the fender is slightly offset from the centerline of the tire. Instead of halfassing it and fighting the small amount of space I had to work with on the bike I decided to just pull the whole rear section of the bike off. While I have this all apart I am going to cleansome stuff up and build an adjustable lowering kit for the rear suspension.
http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0475.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0475.jpg.html)

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0479.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0479.jpg.html)

I also stripped my pipes down to just the head pipe just to get an idea for some different exhaust setups. Kinda makes things easier for me to visualize what I want to do. I am thinking about adding some turn downs and making both pipes stop just short of the rear tire. I will either wrap them with some header wrap or paint them black. I will have to decide on that later.

http://i487.photobucket.com/albums/rr236/Bigskyxj/Mobile%20Uploads/IMAG0479.jpg (http://s487.photobucket.com/user/Bigskyxj/media/Mobile%20Uploads/IMAG0479.jpg.html)

05-21-2018, 11:42 PM

05-21-2018, 11:45 PM
Just decided to do some painting. I'll try and get some good pictures in the sun.84115

05-22-2018, 6:56 PM
Well I am really happy with the paint. It turned out better than I expected. The fender mount is nice and solid. I gotta put a new battery in tomorrow, gonna be doing some riding this weekend. I think my seat needs to be black now that it sticks out like a sore thumb. Maybe I'll try to dye it tonight just for shits and giggles. I see a solo bag in my near future for overnight camping trips.8413584136

06-01-2018, 11:19 AM
Got a chance to get out and do some riding. Also got a nice little solo bag. I'm loving it. I have been checking g out some. LED headlights, I think that will be the next upgrade.8440884409

06-01-2018, 11:20 AM

06-06-2018, 6:27 PM
Nice looking bike man. How did it hold up in the rain with that pod filter on it?

06-15-2018, 11:10 AM
Nice looking bike man. How did it hold up in the rain with that pod filter on it?

It ran like shit in the rain. I ended up getting my factory air box and putting it back on. I'm gonna replace the one air filter with a larger k&n filter and make a cool cover out of a copper pan. Just need to keep searching the thrift stores for a cool looking pan to chop up.

06-30-2018, 8:53 AM
Mounted some knobbies on this old girl last night. My front tire was older than dirt and my rear tire ended up with a big chunk out of it.


06-30-2018, 10:57 AM
Looks awesome. What tires are those? Really dig the look

07-05-2018, 5:49 PM
They are duro hf904. I now have about 250 miles on them and I can safely say that they are waaaayyyy better than the stupid Shinko tire. They corner awesome.

08-17-2018, 2:57 PM
Heres a little video of me and my dad riding this summer.

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