Hey everyone, you might remember me from this post awhile back

https://honda-tech.com/zerothread?id=1770700

that setup worked awesome, I was really happy with how well it turned out. Sold it a few months ago because I was getting rid of the car itself. Seems how my wife and I live in an area where it snows, it just made more sense to get my WRX, and my wife drives a subaru outback. We like Subarus

Anyway I needed a new project and I thought this might be fun. At first I wanted to make some handlebars and maybe change the rear section. That has evolved into what it is today

I know it's not forced induction, but everyone likes a bunch of fab- and this bike will provide plenty of it, plus I missed these forums.

Without further ado;

Specs:
1978 XS650
2004 zx6r front forks
Chrome spoked wheels front and rear
240 rear tire, 120 front
Clip-on bars
Lot's of other good stuff yet to be bought

So here's the concept, I know there's a lot of people lately that will hate on the large rear tire, but since I was 12 I knew that if I ever built a chopper it'd have to have a 240 on it, so that's what I got, and I love it!
The bike will not have a kickstand, the rear half of the frame and the swingarm I will fabricate myself, it will hinge at the bottom frame-rails, and will have an air cylinder attached. When I park the bike, It'll simply set down flat on the frame, then lift up when I go to leave.
The tank will be a standard sportster tank, but I'm going to build an exocage around it to give it some pop.
I'm running the full twin disc front brake setup from a 2004 zx6r-I had one of those before, and I love being able to stop well.
The clip-on bars look hot, but I just might come up with a newish idea (i'm sure someone has done them before) but they'd be clip-on mini ape hangerss. Could definitely look pretty cool

I'm building my tubing bender right now- should be done in a couple weeks or so, as soon as that's ready, I can finish chopping the rear half of the frame off and building the new rear section.

I know this bike isn't very traditional, but I'm all about expanding new borders and new challenges for myself, and I'm thinking that this project has what I'm looking for, and to be honest, I'm very excited with what it's looking like so far.

Progress will be slow because my wife and I are paying off some debt, and we have a limited allowance, but I'm pretty good at stretching money, as I'm sure many of you are as well, Ebay is my friend

Enough talk, Here's the sweet bike when I got it.
Very hot


took it down to the bare frame quickly, mocked up the new forks


Got my wheels and tires, I LOVE this thing



Time to start chopping!



Now keep in mind all that rear frame section will be gone eventually, this was just a basemark because that's about where I'll be sitting on the finished product.





Think I'll be low enough.

And finally, here's my super sweet MS Paint version of what the frame and bike should look like when done.


Comments and critisisms accepted

as of 9/23

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">Originally posted by 04zx6r
I'm building my tubing bender right now- should be done in a couple weeks or so, as soon as that's ready, I can finish chopping the rear half of the frame off and building the new rear section.
</TD></TR></TABLE>

Hah, I make myself laugh- so three months and two welders later, it's finally finished

I finally ponied up and bought a Miller instead of that chinese welder stuff. I feel much better now, plus I can do aluminum, but I don't have a plasma cutter anymore, oh well, the trade off was definitely worth it.
Here's a couple shots of the tubing Bender.
I have realized that drilling large holes through thick metal is NOT my calling in life- that has to rank high on my list of crappiest jobs ever.





I built myself a little table to raise the level of the bike to where I could work on it better, and sort of use it as a frame jig. Don't worry it's not fully bolted down or anything, just used this shot as a reference.
This is basically the length the bike will be when done; 7' 4"
So it's pretty lengthy, but again, now that the bender is done, I'll be able to brace the frame, and cut the final part of the rear section off and FINALLY start building the rear frame sections.




Thanks for looking and hopefully I'll have updates a little more regularly now


couple of quick shots tonight after I fully cut the rear framing off:



Well it's good to be back, and I can't wait to get the framing finished!
thanks guys
Sky

 

Only thing I think is that you should do the shorty drag style bars like you have in that one pic instead of the ape hangars like in the paint mockup.

Otherwise, should be fun.

What drivetrain are you using?

 

i agree about the shorty handle bars, i think they look alot better than the ape hangers. those spoke rims look soooo nice!, i hate those ugly billet crap wheels alot of people put on their bikes! cool project!!

 

i love the creativity. i cant wait to see it finished.

 

Looks liek a very fun project

 

I'm sticking with clip on style bars, but I'm going to make my own, they'll look just like the ones in the pictures, but they'll come out another 6" or so and they'll be drawn a little further back. Should look good.

Drivetrain will be stock XS650- I'm going to rebuild the motor, but it'll be stock. This thing will never be fast, it's just a cruiser, and those motors are super reliable. The only things changed will be the intake, exhaust, and maybe go up a few teeth on the rear sprocket to get that tire moving.

thanks guys
Sky

 

thats bad ***.. i have an old hodaka that i have chopped and put an old honda 125 motor in.. need to finish up the rear though... I want to do a xs650 next!

 

looks good so far keep it up

 

This is going to be cool!!! Good work so far.

 

Nice work man post some more pics

 

love it dude!

 

thats really cool bike your building

 

thanks for the replies guys, I just got the tubing for the frame last night, going to start bending it up tonight.

and clayton, your wife says she misses you.....

 

subscribed! can't wait to see the finished product

 

wow that loooks really cool mang. keep up the great work

 

xs' are fun to cut up

 

nice project...

got the plans of the bender? willing to share?

 

swwweet

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by RACEPAK &raquo;</TD></TR><TR><TD CLASS="quote">nice project...

got the plans of the bender? willing to share? </TD></TR></TABLE>

what he said

 

Got in my tubing last week, was able to get a good start on building the frame.

First off I have to say, to anyone thinking about building one of these tubing benders........DO IT! this thing is awesome! it worked extremely well.

Keep in mind that these peices are just rough cut and set into place with painter's tape but you can see the general shape. I should be able to refine this setup a lot in the next week or so.
Until then, here's some pictures to tide you over.

Looks like just a bunch of bent metal



mocked into place





It's going perfectly so far, I'm really excited because what's in my head is coming out through my hands perfectly.
Stay tuned for the next updates!

thanks
Sky

 

I'm really excited about getting some more updates. Cool project!

Do you have a picture of one of those air suspension setups?

 

Some questions.

Using the stock triples for the shocks? It looks like it. What about the clip ons, are they stock zx6r? Next what'd you use to attach the shocks in front to the wheel? Is that also stock zx6r and you bought a rim set up to fit it?

 

Yep using the stock zx6r triples for the forks, but they're mated to the stock Yamaha steering stem.

The clip on's are also stock zx6r- but I'm going to build my own and sell these

the front wheel is actually a harley wheel, which uses a 3/4 axle. the axle for the sportbike front end is 1 1/4"- i used 1/4" wall tubing from mcmaster carr to slide into the gap. works terrific.

Getting this front end to work on this bike has been a huge pain, but I'm glad I worked through it.

thanks
Sky

 

nice i like that front end rake. Old NORTON FTW

 

sick project