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sweetpotato650
01-28-2011, 9:03 PM
Hey all, Well I thought I would just post up some pictures of where I started. Where I had the bike and where I'm taking it now.
I live in a basement suite so I don't have a garage to work in. This winter I have been working on the bike in temps around 0 to -20 celsius (32 to -4 fahrenheit) pretty usual temperatures in B.C.. I am trying to keep this build as cheep as I can and do everything with what tools I have. I don't have much so I usually try and get creative. Its awesome to come on here and get new ideas from people and see what there doing so let me know what you think of my project.

Where the bike started stock 1981 yamaha xs650
http://i89.photobucket.com/albums/k222/maxritchie/IMG_0822.jpg
Got it to this stage for the summer so I could ride. Cut up the original handlebars and got a friend to weld it all to a drag bar. Lowered the front end and bought some 10in shocks for the back. Also made the sissy bar with a buddy and rewired the bike to very basic wiring. Kick only, no signals, headlight on a toggle blah blah.
http://i89.photobucket.com/albums/k222/maxritchie/35186_447123061806_506961806_6063299_3421440_n.jpg
http://i89.photobucket.com/albums/k222/maxritchie/IMG_0926.jpg
So I started tearing it apart this winter. My wiring was crap, the bike was not charging(a problem the bike had when I bought it, which is why I got it for $700) so I was just going on short rides and recharging the battery. I am collecting parts for a magneto swap but its too much to buy a new ignition system so Im just putting in a stock system(used but all readings are good) and rewiring the bike with that until I get enough money to buy the ignition system/change to points/redo timing which I don't know how to do. Anyways here is the engine pulled an painted in a buddies crawl space, the engine is wet which is why it looks shiny, its a semi gloss black hi temp paint.
http://i89.photobucket.com/albums/k222/maxritchie/f03875d0.jpg
Now I started to do work on the seat rails. Not sure if Ill keep it like this and if I do I will make some new shock mounts.
http://i89.photobucket.com/albums/k222/maxritchie/P1020554.jpg
Here is where I work:
http://i89.photobucket.com/albums/k222/maxritchie/P1020545.jpg

Let me know what you think of the bike. Not much to see where it is now but it will be coming along more and more once my welder arrives.

Hooligans
01-28-2011, 11:01 PM
Seat rails look good like that..... I may not have the weather but I work out of a 10x12 shed so no glamorous garage here either

jamesgs4
01-29-2011, 3:41 AM
I feel ya man, my whole bike was done outside in the driveway.

forty4ma9
01-29-2011, 2:40 PM
Your frame is looking great with that seatpan. Nice work, I'm looking forward to see your progress.

sweetpotato650
01-30-2011, 8:48 PM
Well nice to know some people are in the same boat with the garage factor. I did some work on the neck gussets today just modified the stock to make them look a little cleaner. I think it worked out pretty well.
Made a template and marked it out on both sides:
http://i89.photobucket.com/albums/k222/maxritchie/c598fd72.jpg
Got out the grinder and went at it, rough cut out:
http://i89.photobucket.com/albums/k222/maxritchie/1f7fd4fa.jpg
Cleaned up:
http://i89.photobucket.com/albums/k222/maxritchie/f94ff822.jpg
And with the tank I'm trying to run resting on the rails. The tank is dented to shit and in pretty bad shape inside. I am considering cutting it in half, knocking out the dents and cleaning out the inside. Just not sure which way to go about that. Ideas?
http://i89.photobucket.com/albums/k222/maxritchie/ccd99d48.jpg

a5tach
01-30-2011, 8:55 PM
I'd hack it apart and try to knock them out, whats the worse thing that could happen, you'd have to find a different tank anyway.

Hooligans
01-30-2011, 9:31 PM
Like you said... you could cut it up and try to straighten it, you could also try a stud gun to pull them out. Whats the tank off of?

sweetpotato650
01-30-2011, 11:43 PM
Tanks off a triumph I was told. So what's the best way about cutting it up, should I follow the original weld?

Hooligans
01-31-2011, 12:18 AM
When I cut my Sporty tank - I sat it on my work bench (kitchen counter) nice and flat surface. I used a sharpie with a spacer and slid it on the counter around the tank to give me a nice straight line. On the tunnel curves I just followed the original welds. All cut with a 4.5" grinder

http://i167.photobucket.com/albums/u131/Free89BroncoII/IMG_0280.jpg

http://i167.photobucket.com/albums/u131/Free89BroncoII/IMG_0284.jpg

sweetpotato650
02-01-2011, 2:40 PM
Cut the tank, the inside is so rusty I don't know if it will be useable. I was sanding almost 1/8 of crap. Might try and explore some different options for a tank. Just have to hunt to find something.

snowstorm
02-01-2011, 8:02 PM
I give you and anyone else who works outside in those temps alot of credit. My hat is off to the amature builders who like you prove you dont need a modern shop and a million dollars worth of tools to create a custom bike. Keep up the good work.

SoNorthCustoms
02-01-2011, 8:56 PM
Anyways here is the engine pulled an painted in a buddies crawl space, the engine is wet which is why it looks shiny, its a semi gloss black hi temp paint.
http://i89.photobucket.com/albums/k222/maxritchie/f03875d0.jpg


What brand paint did you use? Any tips or advice for engine painting?

UNKLian
02-01-2011, 9:20 PM
Soak the tank pieces in Vinegar for a couple days.
Scrub, rinse, repeat as necessary.

sweetpotato650
02-02-2011, 1:16 AM
Nice Ill try out the vinegar trick and see how that works out. As for engine painting I just cleaned the shit out of the engine. I bought a small 1/2in I think pipe cleaner and cut the handle off, put that in my drill and ran it threw the fins to lean them out really . Just work hard to get it really clean prep is the most important part of painting I think. I just used a high temp engine paint, not sure the brand name.

jaybee
02-03-2011, 12:59 AM
If you want to get rid of the rust do the electrolysis trick, if you dont know how, I can tell you.

jbee

sweetpotato650
02-03-2011, 10:08 PM
Ive seen the electrolysis thing, now that the tank is all cut open I dont think that would work. Still haven't got around to the vinager thing but will try that out sometime soon. For now I have completed my seat pan check it out.
http://i89.photobucket.com/albums/k222/maxritchie/42effbb4.jpg
I just bought a cheep welder and auto darkening helmet for $230 it came in yesterday. Here is the weld on one of my braces, not to bad considering I haven't welded for about 5 years.
http://i89.photobucket.com/albums/k222/maxritchie/45aff08e.jpg
So I drilled some holes, stuck some bolts threw and welded on the heads, ground off the heads and rewelded to make it a bit stronger. I put some studs on the back with do doh's (for skate trucks) for a bit of cushion.
http://i89.photobucket.com/albums/k222/maxritchie/cd4989fb.jpg
Then I tacked on the top hinge, unfortunatly welding that on I got it a bit hot and totally screwed the threads, so I drilled it out and will probably just put a stud all the way threw with two acorn nuts on either side.
http://i89.photobucket.com/albums/k222/maxritchie/8d80edb1.jpg
Sorry about the crappy cell phone photos, its just easier.

shaaawn
02-04-2011, 5:01 PM
bike looks like it's coming along nicely! Keep it up!!

scout4924
02-05-2011, 6:29 PM
Muriac acid solution of 1-4 or so will clean it right up.

sweetpotato650
02-10-2011, 9:48 PM
Muriac acid solution of 1-4 or so will clean it right up.
Wow, that shit is powerful. When there's smoke from the chemicals coming out of the top when you open it, you know its good! What do I do what it after? I dirty rust water/muriac acid mix in a big bucket right now.

Here is some update pictures. I was going to make a swingarm mount for the rear fender with a little sissy bar but changed my mind. I didnt think the sissy bar would look good but still wanted something I could strap a bag onto or whatever so this is what I came up with. I just have it all welded up. Now I need to clean up all the welds ect.
http://i89.photobucket.com/albums/k222/maxritchie/4e0ca4aa.jpg

I also cleaned up the shock mounts and added a loop where the frame was cut. Looks way better, kind of looked empty before.
http://i89.photobucket.com/albums/k222/maxritchie/853021fc.jpg

Also just got my helmet back from paint, my cousin did the work for me at no charge! Super stoked on it. Not the greatest pictures but you get the idea. I need some new trim for it but it looks awesome.
http://i89.photobucket.com/albums/k222/maxritchie/47c5baec.jpg
http://i89.photobucket.com/albums/k222/maxritchie/1f2e3841.jpg

justinspace
02-10-2011, 10:23 PM
careful man that stuff will mess you up. here, i found this on the webernet. special attention to rule #2 Neutralize it!
prolly not messing with large enough amouts to worry to much about. but were a respirator, outside, by a fan.


How to safely dispose of muriatic acid or clean up muriatic acid spills...
My appreciation Bert Tisher for suggesting I add muriatic acid clean-up and disposal information in this article. It was a huge oversight! Again, an observant reader comes to my rescue!!

Muriatic acid should NEVER be poured down a storm drain, a sink or flushed down a toilet. It can cause extreme damage to pipes, dissolve solder and damage the biological balance of your septic system. Throwing away even a closed container of muriatic acid with the trash can be dangerous for trash handlers, their trucks and possibly cause unexpected chemical reactions in landfills.

Small quantities of spilled muriatic acid will not cause widespread environmental disaster, but it can cause severe damage to plants and animals that may come into contact with it. It's easy to neutralize a muriatic acid spill common household and/or garden chemicals.

Here are some suggestions...

1) Recycle it!
Many counties or cities have drop sites for recycling hazardous chemicals such as oil-based paints and other household chemicals. Most will also accept muriatic acid. Call your local recycling center for more info.

2) Neutralize it!
Earlier, I mentioned using lime (the type used on lawns and gardens) to neutralize acid spills. Spreading a generous quantity of lime (the powdered or crushed type used for lawn or gardens) or baking soda and adding water will cause a distinctive "fizz" as the lime reacts with the acid to produce a harmless salt, water and release carbon dioxide. I prefer garden lime over baking soda since it is less expensive, is sold in larger bags and most gardeners have some laying around!

You can also use lime to neutralize leftover muriatic acid. Get a large bucket. I prefer 5-gallon size dangerous since the chance of dangerous spattering is minimized in a large bucket. Put three of four cups of lime in the bottom and a gallon of water. Give it a stir with a long disposable wooden stirrer (an old 1"x2" is fine). Slowly add the acid to the bucket keeping your face away while pouring (and wearing your respirator). Stir, adding more acid and more lime until all chemical "fizzing" has stopped. The fully neutralized acid can now be safely disposed down a sink or storm drain without fear of damage to your septic system or the environment. NOTE: Remember... always add acid to water, not water to acid!!!!

rustrocket84
02-11-2011, 12:47 AM
It takes a shit load of water to dilute acid. It's actually an exponential factor to neutralize it with water. To take a fallon of a ph 4.8 acid and make it a 5 would take 100 gallons. And at that point it is still a fairly strong acid. That being said I know a lot of people who use the acid treatment to get rid of rust, but also knowing how much damage it can potentially cause and what it will cost you if you get caught disposing of it improperly I just take my shit to a good radiator shop and have them line it while it's there.

sweetpotato650
02-11-2011, 8:07 PM
Well I dealt with that shit today. Also took some pictures in daylight and pictures of the engine painted and polished.
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2208.jpg
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2210.jpg
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2222.jpg
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2215.jpg
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2232.jpg
http://i89.photobucket.com/albums/k222/maxritchie/My%20Bike/IMG_2235.jpg

Salty
02-12-2011, 1:44 AM
helmet looks real nice as well as the what you've gotten done on the bike.

BeetleJuice
02-19-2011, 10:49 AM
Nice work so far man. I'm going to be using truck bushings for seat cushions as well. That lid looks pretty rad.

sweetpotato650
02-24-2011, 7:16 PM
Ya thanks guys I'm stoked on the helmet just ordered some trim for it so hopefully it works out. I just brought the frame, swingarm, handle bars, and pretty much everthing else over to my buddies crawlspace to paint. Still waiting on a tank to come, I ordered a frisco mount sporty should look pretty sick. Ill post up some more pictures once I start getting it all back together.

mikeyfrombc
02-26-2011, 9:25 PM
nice job and where in BC are you ? i,m in Maple Ridge

hornbeck
02-26-2011, 9:38 PM
Looking good, I'm digging the fender mount

sweetpotato650
02-27-2011, 10:18 AM
nice job and where in BC are you ? i,m in Maple Ridge
I'm up in Whistler.

mikeyfrombc
02-27-2011, 1:45 PM
I'm up in Whistler.


nice place used to go there and ride my downhill bike when i was riding , my sister and brother live in Squamish and they hit Whistler all the time

sweetpotato650
03-10-2011, 1:27 AM
Well I finished painting my frame, swingarm, blah blah everything that you see black. I just sanded it down sprayed it with primer then painted everything with semi gloss wheel paint. It seamed to be the best thing to use as it is the toughest thing in a spray can that I don't need to clear coat(I dont like the gloss clear gives off). Everything came out pretty nice for spraying it in a poorly lit, dusty crawlspace.So I put in the engine (with all new gaskets and filters) which was a bit of a task solo but not to bad just didnt want to scratch the new paintjob. Now just waiting on my tank and tail light. Next up fabbing a headlight bracket,taillight/license plate mount and wiring.
Check out the pictures and let me know what you think. Will be working on the headlight bracket next, gotta have this thing almost all back together before next friday!
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2538.jpg
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2530.jpg
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2528.jpg

Beau
03-10-2011, 7:41 AM
Soak the tank pieces in Vinegar for a couple days.
Scrub, rinse, repeat as necessary.


:clap for you::cheersmate:

Yup. Vinegar is the cheapest, BEST thing to clean rusty parts.


Bike looks good man.

Slurpee
03-10-2011, 11:05 PM
Thanks fo posting all the pics man!
Love the way you set up the seat and shock area. I was just staring at my bike last night trying to figure out how I could mount the seat lower without compromising my shock angle too much. You just solved my problem. I like you're gear rack idea too. I'm trying to figure out some kind of rack that I can build a removable seat for so I can take my wife and kid for a spin now and then.
I'm a BC boy too living in Golden, and have been enduring a few cold nights in my little shop. I don't know what your work space is like but I built a little stove in my shop out of a propane tank and it REALLY helps to heat up the space.

poop
03-11-2011, 10:41 AM
pretty cool lookin brat you should be proud of your work

sweetpotato650
03-11-2011, 12:37 PM
Thanks fo posting all the pics man!
Love the way you set up the seat and shock area. I was just staring at my bike last night trying to figure out how I could mount the seat lower without compromising my shock angle too much. You just solved my problem. I like you're gear rack idea too. I'm trying to figure out some kind of rack that I can build a removable seat for so I can take my wife and kid for a spin now and then.
I'm a BC boy too living in Golden, and have been enduring a few cold nights in my little shop. I don't know what your work space is like but I built a little stove in my shop out of a propane tank and it REALLY helps to heat up the space.

I was hoping that I would be able to strap a p-pad on the rack for my girlfriend to sit. But dont think it will be strong enough as is so I might have to rethink it before she gets on. You can see my "shop" on the first page. I moved it to the back of the house now but still basically the same thing.

sweetpotato650
03-13-2011, 1:03 AM
Got my tank in and mounted, one of my buddies made me some bungs for the backbone. Then I made a simple headlight bracket and mounted the headlights to see if I like the look, and I do! So I'll clean those up and paint. Might just throw some clear over the tank, I like the simple paint job for now.
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2587.jpg
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2578.jpg
http://i89.photobucket.com/albums/k222/maxritchie/IMG_2583.jpg

cdnfire
03-13-2011, 3:26 AM
Nice work! Doing my first build in a carport in the Okanagan, so I feel your pain. Love the luggage rack. Think the paint on the motor is a great fuckin plan bud. Think I may have to poach that idea...........:cheersmate:

dckareem
03-13-2011, 9:57 AM
nice job.

Hooligans
03-13-2011, 10:12 AM
man you are moving right along on this.... lookin good though

sweetpotato650
03-13-2011, 11:12 PM
Nice work! Doing my first build in a carport in the Okanagan, so I feel your pain. Love the luggage rack. Think the paint on the motor is a great fuckin plan bud. Think I may have to poach that idea...........:cheersmate:

Nice man, Ill be moving to Kelowna this Friday for school. I don't mind working out side, if life were perfect I'd have a garage but work with what you got right.
Hooligans, I got laid off a couple weeks ago so Ive had lots of time to work on the bike. Plus I have to get this think mostly all back together before I move. Don't have too much left now, license plate bracket, wiring, and some other little things here and there. Hopefully have it on the road soon.

purerockfury
03-14-2011, 10:04 AM
looking good! i like the helmet as well!

Slurpee
03-27-2011, 12:26 AM
Your bike is just getting more amazing by the picture.

I've been thinking about the girl seat problem a bunch. The idea that I've come up with is this:
The seat would have a hook or clamp of some sort that would hook onto the tubing in the center of the back bar. The seat would be raised up to sit 3-4 inches over the highest piece of the rear bumper/luggage rack area. On either side of the seat would be a piece of straight tubing that would drop down to a clip or tab of some sort on the shock mount area. Basically creating a removable cantilevered seat for a passenger.

I think it's going to take some major work and fooling around BUT will work in the end.
I'll keep you posted, if you don't beat me to it.

I'm wondering how you bent your tubes for that seat area as well? Was it a lot of precise measuring or mostly "precise eyeballing" ?

PS. If you're living in Kelowna this summer we should meet up, swap ideas and show off our bikes sometime. Sicamous is a good halfway point and would make a nice ride. As soon as I get a bit more progress on mine I'll start a thread and post some pics.

sweetpotato650
03-27-2011, 3:00 PM
Im not sure I get toe concept of your idea, its just a bit hard for me to picture. I will be welding on some more supports to make the original mount I made a but more stiff. Then making a p-pad with some velcro on it or maybe just leather string so I can attach it to the rack I have already made.
As for the bending of the seat rails. I just cut, then bend, eyeball to make sure my bend is the same. Then I felt it looked a bit empty or wrong without anything behind the seat so I welded on the loop which is the original loop at the back of the frame. I recycled a lot of parts that I cut off my bike. Just like how I made my handlebars from old peices that I had cut off the original handles bars. Good to hang onto whatever it is that you cut off because you never know when you might use it.

Slurpee
03-28-2011, 1:09 AM
I wasn't sure that was going to make a ton of sense... oh well. Sounds like you got things sorted out. What's a P-pad though?

What I really want to know is what you used to bend the tubing?

I have a whole box dedicated to bits I cut off the bike. I figure anything from a mounting tab to a piece of tubing could be re-used no point in chucking it out yet. But then I again I have a bit of a reputation as a junk collector, I like to call it treasure collecting! HA HA!

sweetpotato650
03-28-2011, 4:54 PM
A p-pad is a pussy pad (or i have always thought thats what it stood for) just a like rectangle of foam covered in leather.
I bent the tubing using a map gas tortch, a ratchet extension, and tie downs. Did the back bends first. So heated up the tubing where I wanted, put the tie down strap right where I wanted to make the bend, then put the ratchet extension inside the tubing and pulled it up to where I wanted the bend.
http://i89.photobucket.com/albums/k222/maxritchie/6d72740c.jpg
Then once I got the bends how I wanted it on both sides I heated up the tubing at the front where its welded to the back bone and used tie down straps to pull the tubing down until it touched the tubing at the back where I was able to weld it down.
http://i89.photobucket.com/albums/k222/maxritchie/437be989.jpg
Pictures from my phone but you get the idea. I dont have many tools so I just make due with what I got.

Slurpee
03-29-2011, 2:43 AM
Nice!!!
Very creative. I like that!

JakenBake
03-29-2011, 2:23 PM
Not a bad looking bike. I'm broker than broke so i can relate to what your dealing with somewhat. Temperatures here in Michigan aren't that different than yours..

Slurpee
04-02-2011, 11:22 AM
Hey again,
Are you running your controls in the stock position or are you setting them forward at all?
I'm just trying to posiition my seat right now for stock controls but don't want to end up feeling too cramped. How tall are you and how does your ride feel when you sit on it?

sweetpotato650
04-03-2011, 11:41 PM
My controls are in the stock position. I'm probably 5'9ish, doesn't feel to cramped for me. Plus inlike having my feet under me. Not down with the forward controls.

Slurpee
04-05-2011, 2:59 AM
Arseome thanks!!!
I just installed my seat rails today, felt super cool to sit on the bike in pretty much the exact stance that she'll be rocking once completed.... still a long way to go until then.
I'm enjoying the warmer temps for buliding how bout you?

sweetpotato650
05-09-2011, 9:48 PM
So its been a while. Im back in School so I have been super busy plus the place where Im living for school has the shittiest internets. So Ive made a lot since the last post. Made a licence plate/brake light bracket, pretty standard issue. Also added to the fender bracket I made just drilled some holes threw it and made a good rack for a saddle bag that I can take on and off but just undoing two bolts.
Still have to tune my carbs the jets I put in arent big enought I guess (never really tuned carbs before) but might save up and go with the Keihin Carb Kit from mikesxs. Besides that there are some little things I have to work on, like a kickstand, right now I just built a little one that I have to throw in once I stop but it would be nice to be able to just kick one out.
Anyways, I think it turned out pretty good (not to bad for my first build). I dont like how much shit is coming up to the bars. But what can you do. Check it out, let me know what you think.
http://i89.photobucket.com/albums/k222/maxritchie/P1020646.jpg
http://i89.photobucket.com/albums/k222/maxritchie/P1020644.jpg
http://i89.photobucket.com/albums/k222/maxritchie/P1020636.jpg
http://i89.photobucket.com/albums/k222/maxritchie/P1020635.jpg
http://i89.photobucket.com/albums/k222/maxritchie/P1020631.jpg

jamesgs4
05-10-2011, 5:50 PM
Looks good! you could get rid of the front brake switch, and those bars look like an internal throttle would feed through maybe? old airhead bmw's had cable actuated remote mount front brake master cylinders that you could hide on the bike somewhere.

sweetpotato650
05-10-2011, 11:43 PM
Thanks man, Im liking the facelift you gave your bike too. And the sprocket sizes you reccomended are way better at highway speeds so thanks for that! I guess I'll keep picking away and trying to hide more and more. Front brake switch wires would be easy, where can you get an internal throttle/cable?

SeaChicken
05-11-2011, 2:34 AM
The bike is awesome man, I like what you did with the lights and barson that bad boy.