HOW TO: xs650 frame with modern HD front end

[mreed]

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

[Guest]

Nice!

[bobberadam]

Awesome, thanks!


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[mikeylikesitt]

hell yeah, very cool

[liquidlife1991]

can you do something like this to a kz750?

[mreed]

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.

[Ato]

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.

[TwistyMcFisty]

^^^ yep.

[farmall]

Slick and well done.

That trick would work for many front end swaps because it avoids doing anything complicated to the original neck and the plug weld gets rid of the fugly fork lock boss.

"Timkens"/tapered roller bearings are not just sold as what you get when you order "HD neck bearings", they are also sold with different inner and outer race diameters.

For example you could choose a different inner race which fits the Harley outer race, and if need be turn your new fork stem down slightly (don't weaken it) to fit.

[sgilliesjr]

stock neck

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

[farmall]

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.

[sgilliesjr]

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

[mreed]

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.

[TimberwolfFXDL]

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

[sgilliesjr]

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!