Braking news!

I had originally planned on using the TC Bros forward controls, brake pivot and linkage kit for my build, however have decided to stick to mid mounts for now.

I did however decide to utilise the linkage kit for the bike.

This struck it's own problem, especially considering how I was going to attach the rod end to the brake arm upon the rear hub.

I think I've come up with a pretty elegant solution that will work well and look good.

I simply found a shouldered bolt (Allan head) that was the correct diameter to fit within the lever. I had a thread machined into the bolt, and there you have it!

Wheels before and after

Here's a handful of shots showing the progression of the wheels from rusty and grimy to freshly rebuilt and powder-coated.

I laced the rims myself taking advantage of the Fong Bros fantastic tutorial, with the truing and tyre mounting taking place tomorrow via a pro shop.

I also plan on getting the axles, nuts, rear sprocket and bolts black nickel plated.

 

Still ugly!

2 1/2 weeks, and still no prettier!

Keep those donations coming!

http://au.movember.com/mospace/810250

All Forked UP!

After a lot of effort, I've finally got the lower fork tubes very close to a finish that I am happy with.

It took close to six attempts including a failed powder coating effort to get them to where they are now.

Unfortunately the original plan of powder coating them gloss black failed due to an out-gassing issue that created a significant amount of bubbling upon the finish. After having them powder coated by a friend of a friend, it was all too messy to get my back up over the situation, so I attempted to fix them myself.

I decided to simply sand back the powder coat with 600 grit wet and dry, to get it back to the blemish free surface that I'd originally had.

I utilsed the VHT roll bar spray paint and subsequently covered it as directed. I did however, manage to stuff up my hard work (more out gassing) after deciding to bake them in the oven to try to obtain a better gloss result.

Needless to say, after much trial and error, I now know the correct recipe to getting the quality of finish that I require. This process also includes a liberal coating of clear coat.

All that's left now is to remove any tape, install fork seals and re-assemble the front end.

Donate to prostate - Movember

G'day all.

I'm spreading the word that I'm captaining a Movember team, with the objective of growing the meanest baddest soup strainer to help raise donations to fight prostate cancer and men's depression.

Any donations and support of the Movension Studios team would be greatly appreciated, and going to a very worthy cause.

http://au.movember.com/mospace/810250

All participants are required to be clean shaven on Nov 1st, and let the lip run wild for the month of November. I'm going for the combination of trucker and Uncle Chop Chop.

Barred up!

Here's a random shot of the bars, triple trees and risers all mocked up.

Black is back!

Tonight I had the opportunity to piece together the rear and front hubs after getting them back from powder-coating.

My rims will be back early next week, which will allow me to start stringing them together. I plan on visiting a pro for the rim truing and tyre mounting.

Didn't turn out too badly!

 My triple trees were also powder coated gloss black too.

Royal replacement

To my pleasant surprise, Royal Spares were very helpful in getting me a new tool bag sent out to me  last week, in the colour that was originally requested. It only cost me the delivery charge, whilst they were happy for me to keep the red-brown coloured version as well.

It actually matches the Rich Phillips seat perfectly!

She's coming together!

It's been a big couple of weeks with the tank and chassis welding having taken place.

Arthur from North Shore Radiators did a great job of soldering my tank back together, cleaning, sealing and pressure testing it to ensure a leak free result.

This long weekend was spent removing any slag from the chassis welding, and just giving it all a once over as I move closer to getting it prepared for powder coating.

Other than the seat sitting too far forward, it's easy to see how all of the elements are coming together.

Tight squeeze!

As part of today's mock up session, I wanted to test out the fitment of the coil that came in my Pamco ignition kit from Mikes XS and the backyard slimline engine mounts that I'd made up.

Talk about a tight squeeze!

Getting bent!

It was always my intention to have a fender stay that was as discreet as possible, with it preferably running under the fender once attached.

My solution was to grab one of the Triumph fender stays that Steadfast Cycles sell.

Unfortunately it was way too narrow to suit my application, however, with some careful re-bending it now clears my 4.5 x 18 Firestone tyre. It was also way too short to clear the wheel, so I decided to give myself a flexible fix. This called for some 10mm threaded rod and rod ends.

Now I have an adjustable fender stay!

Getting a handle on things

Yesterday was a big step to getting the bobber well and truly under control. The chassis was delivered to get welded together.

I'm also getting key parts of the bike sandblasted over the next couple of weeks in preparation for some powder coating.

I started to assemble the handle bar and switch gear throught the week.The parts include a TC Bros Drag Bar, Mikes XS right side switch, throttle and master cylinder, Posh grips purchased Deus Ex Machina and left switch from Motorcycle Recyclers.

 

Part of today's research was locating a suitable supplier for a single piece braided brake hose to run to the older style caliper. This is a Mikes XS complete early caliper that they sell, with a 10m x 1.0 banjo bolt which happens to suit the same thread and pitch that originally utilised a hard line fitting arrangement.

What a tool ..................bag!

Didn't get too much done this weekend, however, I managed to get all of the metalwork prepared for welding and pressure testing of the gas tank. Once done, prep and painting can begin.

Mounting of the ignition switch was also performed, with just enough clearance available between it and the tool bag that had arrived during the week.

Unfortunately I wasn't quite delivered what I'd ordered, with the tool bag having much more of a red/brown finish, rather than the tan coloured version that was expected. With the supplier Royal Spares being all the way in India, I just couldn't be bothered trying to fight it, and decided it might not be too bad after all. It kind of matches the copper milk urn and outside edges of the seat.

As you can see, it was an opportunity to mock up the gas tank, hard tail, milk urn, tool bag and seat. The seat is definitely well too far forward, and will likely be another 70mm further back. This will get determined when I'm mocking up the rear fender position.

Talk about service!

To my disbelief, an order of new shiny, or in this case black coloured bits arrived from one of the parts suppliers, Webike, that I had discovered.

Amazingly all of my parts arrived in a record time of only 4 days from Japan to Oz! As much as I'd like to support the local guys, you can't beat 30-40% cheaper pricing and free shipping!

Ofcourse I had to do my usual ritual of a test fit the moment I walked in the door last night.

In the shots below you can see the 5 3/4 Bates replica headlight, headlight bracket, blinkers and 49mm Bates style taillight that I'd ordered from Webike.

I also did a test fit of the XS650 specific blinker stays from Motolanna and a headlight grill from a local ebay parts supplier.

Beyond the point of no return!

I took the plunge and finally committed to the hardtail today by chopping my chassis up.

The TC Bros instructions were very straight forward and are a good guideline as to what prep is required prior to final welding.

For all of you seasoned bike builders out there, you will notice that I don't have a motor mount brace to keep the down tube and chassis rails true. I was fortunate to acquaint myself with a very helpful member of the XS650 Club of Australia who is providing me with valuable advice and a helping hand. Thankfully he has an amazing jig that will help square the chassis prior to welding.

Of course, as any excited bike builder has done, I had to do a test fit the first chance I could.