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  1. #1

    Join Date
    Dec 2010
    Posts
    448

    Default HOW TO: xs650 frame with modern HD front end

    stock neck



    remove fork lock mess



    remove the "belled" ends of the neck







    make an insert for the now hollow neck. The o.d. of the insert should match the neck's i.d. and the i.d. of the insert should match HD neck cup's o.d. I start with a tube that's just a bit larger and turn it down for a press fit



    I also put a small bevel inside each end. Makes pressing in the neck cups a little easier



    pressed in



    At this point you can weld the hole left from removing the fork lock. This will also help hold the insert in place.

    neck cups pressed in





    front end installed



    The cool part about this is that we were easily able to swap standard neck cups with 3 degree raked cups to help the stance

    Last edited by mreed; 11-15-2013 at 5:42 AM.

  2. #2
    Jetblack
    Guest

    Default

    Nice!

  3. #3

    Join Date
    Jan 2011
    Posts
    423

    Default

    Awesome, thanks!


    Sent from my iPhone using Tapatalk

  4. #4

    Default

    hell yeah, very cool

  5. #5

    Default

    can you do something like this to a kz750?

  6. #6

    Join Date
    Dec 2010
    Posts
    448

    Default

    Quote Originally Posted by liquidlife1991 View Post
    can you do something like this to a kz750?
    I imagine this could apply to any neck that is larger than a stock HD neck.

  7. #7

    Join Date
    Oct 2010
    Posts
    763

    Default

    You should consider making a few of these inserts up and selling them. I'm sure more than a few people would be interested. I know I would if I was doing an HD frontend swap.

  8. #8

    Join Date
    Aug 2010
    Posts
    294

    Default

    Quote Originally Posted by mreed View Post
    stock neck



    That's pretty slick! What did you use to cut that neck?

  9. #9

    Join Date
    Apr 2013
    Posts
    8,530

    Default

    A six-inch cutting disc (use the thin sort, .040 or .045") in an angle grinder will make short work of cuts like that. (6" beats smaller discs in reach, longevity and edge speed. A 4.5" grinder motor will drive them but mod the blade guard to fit if you value your fingers.)

    You can also use those discs in a circular saw if you use a couple of washers to adapt them.

  10. #10

    Join Date
    Aug 2010
    Posts
    294

    Default

    Damn dude, you have a much steadier hand than I do! I could never cut that straight with a angle grinder!

  11. #11

    Join Date
    Dec 2010
    Posts
    448

    Default

    Quote Originally Posted by farmall View Post
    A six-inch cutting disc (use the thin sort, .040 or .045") in an angle grinder will make short work of cuts like that. (6" beats smaller discs in reach, longevity and edge speed. A 4.5" grinder motor will drive them but mod the blade guard to fit if you value your fingers.)

    You can also use those discs in a circular saw if you use a couple of washers to adapt them.
    no, not an angle grinder. I use a 3" pneumatic cut off wheel. I never use an angle grinder for cutting.


  12. #12

    Default

    I've been back to this thread a half dozen times. I am using the same technique to put an HD front end on an old Honda Scrambler frame. Already have some DOM tubing waiting for the lathe. As soon as the bearing cups get here I'll be making chips and sparks thanks to your inspiration

  13. #13

    Join Date
    Aug 2010
    Posts
    294

    Default

    Quote Originally Posted by mreed View Post
    no, not an angle grinder. I use a 3" pneumatic cut off wheel. I never use an angle grinder for cutting.
    That still takes a pretty steady hand to get it straight, even more so with those stiff pneumatic hoses!

  14. #14

    Join Date
    Dec 2010
    Posts
    448

    Default

    Quote Originally Posted by sgilliesjr View Post
    That still takes a pretty steady hand to get it straight, even more so with those stiff pneumatic hoses!
    It's just what I'm used to. I imagine if you were to fashion a chop saw blade to a weed whacker and used it every single day you would eventually become rather accurate with it.

  15. #15

    Default

    Gday Iím just wondering what the outside diameter of the insert or the I.d of the neck?
    Just so I could make the insert before cutting the neck of my frame up

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