HOW TO: xs650 frame with modern HD front end

[mreed]

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.

[farmall]

He's right. It's all repetition.

A piece of masking tape helps hold lines on stuff that doesn't mark particularly well.

Note that I don't use a large-motored angle grinder. 6" Metabos etc are the same physical size as smaller grinders and will cut 3/8" steel plate if you let the wheel float and take your time so you don't overheat the motor. I like die grinders too but dat 6" surface speed is the shit. I hadn't used one until the pipe welder instructor I worked for showed me why they are so popular.

BTW if you want a kickass, tough electric die grinder the Milwaukee 5196 is sweet. Even welding students rarely kill them and they could break a bowling ball with a feather. They aren't small but they'll run the fuck out of flap wheels and cutting discs. I like electric die grinders for the torque. They aren't cheap at about three bills, but if you have a shop or just like good gear get one.

[TimberwolfFXDL]

Finally got to try it out... check it:
Since nobody makes a HD to Scrambler bearing swap kit, I made my own. This is the neck insert made from DOM tubing turned to the ID of the Honda neck, and bored for an interference fit with the Harley bearing cups.



Here's how that project starts. If you measure between the integrated bearing cups on the Honda you'll find they are 5.625" apart. Coincidentally, that's length of a factory Harley neck without cups. So, we carefully lop them off (only one had been cut off when I took the pics)...



Home grown press installs the neck bushing.

spot welded, then bearing cups pressed in.

Forks installed

[mreed]

^ beautiful work. Very cool.

[TimberwolfFXDL]

^ beautiful work. Very cool.

thanks man! I wouldn't have tried it if it weren't for this thread!

[Trav101]

Any one making these yet?? seems a good idea. If the price is right Ill take one.

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.

[LarryBrown]

Awesome info, Thanks!!!

[inkedmonkey]

I need a lathe....

[Trav101]

there's money to be made here. yes, you need a lathe. You could put together a kit that includes the insert, bearing cups, and directions where to cut. After that just collect your 100 dollar bills.

[warehouseskate]

i could easily make some of these for anyone interested, would be a fun quick job actually.
pm me here or at vanguardmachine.com

[mreed]

i could easily make some of these for anyone interested, would be a fun quick job actually.
pm me here or at vanguardmachine.com

Voodoo Vintage is making them now. They're on their site. If you buy one, tell em the dude that started this thread sent you lol.

[Wulfie]

Wow this is a great thread, I am considering changing the front end on this bobber I just bought, but not decided for what yet, the question I have now is what did you use to cut the lock off the headstock, I'm guessing it was the same disc that features in the other posts which is cool, but what did you use to then restore the surface profile, reason being some buffoon that previously owned my bike has welded side panels onto the frame (badly) which need cutting off (pic attached) but then I need to remove the remaining weld and stuff from the frame, just not sure what to use, advice would be gratefully received, btw I am very new to this modding game, but plenty of experience with bikes.

Cheers

Chris

[inkedmonkey]

I cut my lock off with a cut off wheel. Then just welded up the hole and ground it smooth.

[Wulfie]

Thanks

[farmall]

A flap disc does a much nicer job than a grinding rock and moves plenty of metal.