I know everyone wants to see another build thread....

Well, here is mine. I bought a 1980 XS650 from a friends dad about 2 months ago. It had sat outside for more than 3 years without being started. I brought it home, put some clean fuel in, drained the carbs, put some jumpers on the wires from a good battery, and after a dozen kicks, the bike started. Hell Yeah! So I decided that I was going to make a bobber out of it. The bike will ultimately have a magneto kit and pamco ignition and run without a battery.

Here is what it looked like to start with. Obviously my kids are excited over the new project.

So then I build a stand to put it on for the assembly/disassembly.



Then the teardown began. I am not using most of the parts, but the ones that I am keeping will be stripped and powdercoated. I do powdercoating as a side hobby for me and others, so that will keep some of my cost down.

I didn't like the original neck gussets, and since the tank is going to be an axe or alien tank, I wasn't too worried about how it was going to mount since they mount to the backbone of the frame. I also removed the bar for the stock ignition coil mount, but kept the upper motor mount. I think it looks cleaner with the open frame. I will have to find a new place for the wiring and coil. I am thinking of a fake steel ball in the rear of the hardtail.

Then the fun stuff. I cut off the rear of the bike. I bought a hardtail from Lowbrow Customs for this build. I liked that hardtail because of the gussetting and frame weld coverings they come with. It was a little more expensive, but I wanted that one. I don't have any tig welded pictures yet, but I have the ones of how I tacked it in place.

This is where I made sure the frame was square and even.

I decided to cut the tabs off the front forks, powdercoat them (including the uppers except where they go through the fork seals), and use gators to hide that area. They were pretty pitted from being outside in the elements for a while, and I couldn't sand them out enough. My only problem is I have to make the opening in the trees slightly larger, from 1.35 inches to 1.4 inches to make up for the powdercoat thickness.

I then took the front wheel apart. I replaced the bearings and am going with black mini-texture powdercoating and stainless steel spokes. I have them mounted (never did that before and it was a pain in the ass) and I need to learn how to true them up.

The last thing I have done was to build a mount for the solo seat. This is where the build stands for now.

Are you doing the poweder coating yourself?

Looking good.. I'm digging into my xs650 as well.. previous owner did his 'version' of a hardtail and I'm fixing it up as of now.

nice progress!

Those forks look amazing!!! Whole build is looking great!

Originally Posted by thelowlife

Are you doing the poweder coating yourself?

Yes, I do powdercoating as a side hobby/business. I am in the process of researching a 4 x 4 x 7' oven. Right now the one I have is 2 x 2 x 5" that I built. I will be building the next one also, but it will be a modular unit as to not lose any more garage space than I have to.

Thanks, everyone, for the positive comments. This will be a slow process, but I am learning a lot along the way.

Wouldn't you know it. That mount for my seat had to be cut off yesterday. When I welded it in, it moved forward on the left side about 1/8". That made my seat off on the rear part by almost a full inch. That sucked. Now I have to redo it because I am not going to live with that.

amazing build and progress! did you find instructions online for building your own oven? or is it something you buy and assemble? been thinking about home PC'ing stuff me'self.

I like the way you took out the ignition coil bar, it made a big difference. Keep us posted!

Mmm I like me those forks. Lookin fwd to seeing the final on this one!

OK. So I redid the seat mount. I just showed it mocked up with the seat and my hand in the way. I have the towel keeping the powder coating from being scratched by the bracket I made to go on the mount. (I need to start using my regular camera instead of my phone. Sorry for the grainy pictures.)

So I was able to fix my seat mount, and install the bungs for the 3" hairpin springs, or scissor springs as they are called as well. I also scored a set of risers for 1" bars off of a Vulcan for $20. They are aluminim and should coat up nicely. I have to powder coat a panel for someone this weekend, so I will be doing the seat mount I made as well to give an idea of the color I will be putting on the frame. All of the hardware that I am installing and replacing is going to be stainless steel, also. I though about polishing it all, but I think it will look better with the darker colors of the bike and they style I am looking forl.









I am now going to have to focus on making the triple trees a little larger in diameter to fit the forks with the powder coating on them. But for now, I also have a 1982 XS650 that I will be eventually making into a cafe racer style bike. I am going to use the forks off of it to get the stance of my bike right so I don't have to put the finished ones in and out and chance messing up the finish.

I have also thought about my speedometer issue. I think I am going to put in one of those aviation air speed indicators and use the spacer that Hugh fabricates from Hughshandbuilt to replace the gear on the front tire. I think that would be pretty cool, and different.

I also just received my magneto kit from Hugh today, and although i am not ready for it yet, it was too good of a deal to pass up. Thanks for the deal, Hugh, and the fast shipping.

The only issue with those risers is that they are about a 1/2" short to go through the stock bushings. However, I think that the bolt is cast into the aluminum. That means that I will have to cut the old one off, then drill and tap for a new bolt. But I am going to try and heat the riser a little first to see of the bolt will come out. It may be threaded in and held with locktite. Hard to say. I am hesitant on this and don't think it will, but am gonna try it first before I start cutting.

What about a new top clamp, then you can just drill holes for the risers.
http://www.xs650.com/forum/showthread.php?t=10214

I can custom spin you a set of riser bushings, that will counter sink that riser into it 1/2" if needed. Trust me, that hardware isn't coming out of those risers, they look like V-Star stuff, and I have used it before... Let me know if that helps you out any...

Hugh