PDA

View Full Version : '06 Yamaha XVS 1100 Re-build - "The Foreigner"



tramskitcher
01-05-2017, 1:46 AM
Hey,
I finally made the move to re-build/chop my '06 XVS 1100 v-star over winter here in Australia.
I was never happy with what I had already done to the bike. More so the stock frame (You know,that ugly double backbone!) and that fat rear tire, I hated walking up behind and seeing that fat ass tire.

In saying that, to me it was just a patch job to get me through last two summers on a bike that I was happy to ride and looked good enough for the mean time, I have really wanted to do this for the last couple of years now.
As an a apprentice sheet metal fabricator, I was waiting until I knew I had the skill and foresight to chop my frame and design it to work the way i wanted; working around the engine with the lower half of the stock frame.

I'm still learning everyday, so I don't claim to be a know-it-all. But if I was to do this I would do it once & do it right. I have a passion for motorcycles and fabrication. Thats why 3 years ago at 28yo I made the move too work with metal and get into the trade. I did lots of reading and would learn of a lot of guys in different fields and would soak up all the advise anyone would give me and take it on board.

So the first thing to do was decide on where I wanted to be at the end and work from there.
I wanted to build a SoCal 60's Frisco bike.
The bike is appropriately named The Foreigner, because I'd be making stuff on my lunch breaks or after work doing foreigners :cool:

Pics in order.
-Stock pic of what it looked like when i got it.
-Changed a few things
-Version 2
-Last day of riding before the tear down

21guns
01-05-2017, 2:16 AM
Looks really good dude. I actually am in the same situation myself just at a younger age. What are you thinking paint wise and getting it regoed depending on your state?

tramskitcher
01-05-2017, 2:18 AM
Tore the bike down, and made a engine stand for the bench. The engine is a two man lift. It is heavy!
My little workshop is 6ft by 19ft. Its small but snug. Perfect for me. It under went a lot of changes to utilise all the room I could over the last 8 months.
I brought a JD squared model 32 bar bender, die set and JD squared Tube notcher along with a heap of new Makita Brushless power tools to assist me.

I had plates laser cut so I could make a jig to hold the frame together and a friend turned down some neck cups to hold the neck in place. I cut the frame while it was inside the jig, and it worked perfectly, the frame didn't move at all.

I also got the 3/4 HD axle to stock XVS dimensions for the 21" wide glide wheel conversion.

I bent the 1 5/16" seamless pipe to the desired angle for the seat area and cut the back bone and notched the pipe to the correct angles. Cleaned up the neck area, the stock frame has some terrible robot welds, so I cleaned and re-did some of the welds. They were big cold welds.

tramskitcher
01-05-2017, 2:27 AM
More pics from previous post

TheMainMuel
01-05-2017, 2:37 AM
Right on man. Great progress. I want to do the same with my 1100, I'll be keeping tabs. Love the shop too!

tramskitcher
01-05-2017, 2:55 AM
More pics from previous post

tramskitcher
01-05-2017, 2:59 AM
The jig worked perfectly, the frame didn't move at all. I laid out the backbone to get the right look and then I put it in the frame and tacked it altogether. I also covered the steering lock hole form the stock main key on switch. I added a extra bar to the neck for support.
I then proceeded to weld it up. I wasn't going to run the stock front end. It was far to wide so I then took the frame to my friend who put it inside the CNC and tuned the neck to take HD 1" racers and bearings so I could run a HD Sportster Narrow glide front end. He did a awesome job and it works perfectly.

tramskitcher
01-05-2017, 3:08 AM
Pics from previous post

tramskitcher
01-05-2017, 3:13 AM
:)

tramskitcher
01-05-2017, 3:20 AM
I then moved to making up a engine mount to suit. This was a little tricky as I had to re-design it, and it had to be able to be detachable from the engine and frame or it wouldn't work. This is a pic of the progress of it.
Next was the tank, I got it from Throttle addiction and proceeded to TIG welding it up, I got real nice corner to corner prep. I added in a mini 1-5/16" Weld in bung for the gas cap along with fuel sight bungs on the left hand side and NPT fuel outlet bung to the bottom left. Also made the handle bars that are super comfortable and to suit the style of the bike.

I had the 21" and 16" wheel striped of chrome and powder coated white. Laced with new stainless steel spokes. I used the stock rear hub but put into a aftermarket 36 hole rim. I used Avon SPEED master tires.

tramskitcher
01-05-2017, 3:30 AM
Pics from previous post

tramskitcher
01-05-2017, 3:42 AM
So I knew the 16" wouldn't fit inside the stock swing arm, I made a jig to hold it in place while i cut it up. Most nights that I had to work outside, it was a chilly 1 degree (33F) it even snowed one night. Called it early that night!
I extended the swing arm by 15mm to allow room for the new tire and rear fender. I cut it up and reduced the down tube section and replaced with new material. Then I turned down some pipe to sleeve into the extension/ stock part and plug welded it in. I welded it back together and it worked out perfect! Pressure tested the tank as well. No leaks!

I wanted to have mid mount pegs, so i had to work with the frame and unused space that i had. There was literally on one place I could put it. So had no choice, I moved the rear master cylinder assembly back along with the foot controls 200mm to the rear.
Fabricated a mounting plates for the LH & RH foot controls. I used the existing holes in the frame to mount the LH foot controls and kickstand. And a new rear brake pulley that works over the top of the exhaust I made.

tramskitcher
01-05-2017, 3:55 AM
pics from previous post

tramskitcher
01-05-2017, 3:59 AM
:)

tramskitcher
01-05-2017, 4:28 AM
I got the lowering links laser cut in 5mm (15/64) Stainless Steel. I sell these online at www.barnonemoto.bigcartel.com in 12 different heights.
The bars came back from chrome, I had added the holes to take internal wiring and mini switches.
I finished off the frame along with welding in the bungs required etc. I had to notch of a small section of the backbone to allow the tappet cover to fit underneath. I rolled into shape a small piece of metal the same thickness as the tube. I got a nice corner to corner fit right the way round. Once it was welded, I used a torch and looked up the backbone to see the penetration. I had full peno right round which was quite relieving.

I wanted a cool looking sissy bar so I took extra time on this. I made little tabs for the tail light wires to run through too. Fitted the fender and welded it off.

I was going to run the same solo seat, but this time I put locating holes for the seat to sit in nicely and not move. Torn it back down for the frame to painted.

tramskitcher
01-05-2017, 4:40 AM
Pics from previous post

tramskitcher
01-05-2017, 4:51 AM
:)

Frost
01-05-2017, 7:21 AM
man this is awesome

tramskitcher
01-06-2017, 5:11 AM
man this is awesome

Cheers dude!

tramskitcher
01-06-2017, 5:12 AM
Right on man. Great progress. I want to do the same with my 1100, I'll be keeping tabs. Love the shop too!

Cheers man, love my little shop!

tramskitcher
01-06-2017, 5:13 AM
Looks really good dude. I actually am in the same situation myself just at a younger age. What are you thinking paint wise and getting it regoed depending on your state?

Paint is sorted. I'll post a pic soon man

tramskitcher
01-07-2017, 7:26 PM
Did I say paint for the frame? Yeah, there was a miscommunication about that. Instead of getting blasted only, it was powder coated as well.
I decided to run with it as I was pressed for time. Never the less the powder looks great. And the chrome came back awesome as well.

tramskitcher
01-07-2017, 7:35 PM
My friend did the paint, it came back looking real good; along with everything else I had fabricated.
Like custom stock sized battery box, engine support bracket, electrical box, kickstand and food controls.

I changed the K&N filters to a smaller slimmer size which look heaps better for the bike, and moved the rear master cylinder from the front of the bike to the middle section and mounted off the frame. I turned down some sleeves to cover the all-thread.

tramskitcher
01-07-2017, 7:40 PM
Pics from previous post

tramskitcher
01-07-2017, 8:34 PM
I re-wired the entire bike. All the plug originally connected near the neck, so lengthened the wires and I made a small box that fits under the seat to house the new wiring connections. I also re-located the rear coil to the the box and then put the front coil mounting off the carby. The regulator is mounted to the rear of the box while the Dyna 3000 ignition is inside.
I internally wired the bars along with using mini switches for a clean simple look. The start button is now on the LHS of the box, next to the main key switch.

The bike is finally finished! Such a relief. There were a few hiccups along the way which delayed the project. But the hardest part about the build was figuring out how to do certain things that have not been done before. And then making up that part to work. I did research to see if anyone had done something similar, but no luck. So to the best of my knowledge this is a first you could say.
People would say why didn't you just buy a Harley!? Well, A. I don't have spare money for one, so I was going to use the bike I had and B. I wouldn't get the same challenge, that I got with this.

Thats when I'd be alone in my workshop without any help or music, just sitting there stuck thinking in my own head; nutting it all out. With the odd helping hand to help, like to pull out the engine back and forth, in-out-in and so on.
I worked on it most nights after work for a 4 hours or on the weekends when I was home from being on-site for work. I make sissy bars and handle bars for various different Harley and metric bikes for people (@bar_none_moto) in my spare time to keep the passion flowing, but towards the end I had to halt all orders so I could focus solely on my own bike.
My wife is very supportive and I'm stoked she put up with me not being around as much.

So to clarify the basically only part of the bike that is left unmodified from stock is the shaft drive & rear hub. Everything else has been fabricated/deleted or modified.

tramskitcher
01-07-2017, 8:44 PM
:)

tramskitcher
01-07-2017, 8:58 PM
Here are some pics I took after my first ride.
It is so fun to ride, I couldn't be happier to riding again and I love the new position of the mid-controls. It is so good to back riding. Looking forward to a 10 day moto camping trip in Tasmania (the little island at the bottom on Australia) http://www.google.com.au/maps/place/...855,143.915777

tramskitcher
01-07-2017, 9:02 PM
The before and after shot.

TimRiumph
01-08-2017, 8:10 AM
You did a great job man, you should be real proud! -Tim :)

Westboundbiker
01-08-2017, 9:01 AM
Amazing build dude. Super clean- I love it!

tramskitcher
01-09-2017, 1:31 AM
You did a great job man, you should be real proud! -Tim :)

Much appreciated dude!

Reflexion
01-10-2017, 8:48 PM
Impressive. Plz Let me know when u want to sell that thing

TheMainMuel
01-11-2017, 5:11 AM
Wow man, bike is so rad! I love that exhaust!
I started following you on IG. You need to post some pics of the bike on there.

Frost
01-11-2017, 8:12 AM
love it!

LeDom
01-11-2017, 4:19 PM
Glad I clicked on your thread man, this bike is sick good job

DrFxr
01-11-2017, 6:40 PM
Nice work man!

Sikwitit
01-12-2017, 10:09 PM
Bad ass man. Great job

mikecola
01-13-2017, 4:50 AM
nice work. looks really good

tramskitcher
01-25-2017, 1:02 AM
Impressive. Plz Let me know when u want to sell that thing

Thanks man!

tramskitcher
01-25-2017, 2:20 AM
Wow man, bike is so rad! I love that exhaust!
I started following you on IG. You need to post some pics of the bike on there.

Cheers man. Whats your IG name?

tramskitcher
01-25-2017, 2:21 AM
love it!

Thanks man!

tramskitcher
01-25-2017, 2:22 AM
nice work. looks really good

Appreciated dude

tramskitcher
01-25-2017, 2:22 AM
Bad ass man. Great job

Cheers man!

tramskitcher
01-25-2017, 2:23 AM
Glad I clicked on your thread man, this bike is sick good job

Glad you enjoyed it

LeDom
01-25-2017, 2:34 PM
Great job man, could you tell me how you rewired the key switch?
I am in the process of doing so and cant figure out a way to get it right.
thanks!

tramskitcher
02-05-2017, 7:03 PM
Great job man, could you tell me how you rewired the key switch?
I am in the process of doing so and cant figure out a way to get it right.
thanks!

I used the Lowbrow waterproof switch. http://www.lowbrowcustoms.com/weatherpoof-starter-ignition-switch.html
I only used A & B on the switch. "A" has RED/BLUE and "B" is RED
The stock switch has four wires, so the other two were wired off into each other.

74797
Wire colours [/B]

LeDom
02-05-2017, 7:33 PM
Okay so I guess you kept a on/off switch and a push button?
Im trying to wire it so I can use only the key to start the bike

tramskitcher
02-11-2017, 8:15 PM
Okay so I guess you kept a on/off switch and a push button?
Im trying to wire it so I can use only the key to start the bike

I'd get a auto electrician to do it for you man. It would be easy for you that way

BreathingFlames
03-08-2017, 6:15 PM
Very Nice Welding and Work laying it out . .

Joseph77
03-30-2017, 1:25 PM
That 1100 looks killer. I'm thinking of doing a single backbone on my 1100 Classic some time down the road. Where did you find the 90 bends for the air cleaners? I'm still using the stock bends with my filter pods.

tramskitcher
06-18-2017, 5:48 AM
That 1100 looks killer. I'm thinking of doing a single backbone on my 1100 Classic some time down the road. Where did you find the 90 bends for the air cleaners? I'm still using the stock bends with my filter pods.

Got them from here man - www.sloneservices.com/metric-magic/DragonsBreath.htm

tramskitcher
06-18-2017, 5:48 AM
Very Nice Welding and Work laying it out . .

Thanks man

tramskitcher
05-18-2018, 9:44 PM
Bike is now up for sale