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Cycle Fabrication Old School, Choppers, Bobbers, and Customs


Cycle Fabrication Old School, Choppers, Bobbers, and Customs

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  #1  
Old 08-01-2010, 04:05 AM
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Chopper rebuild time!

Ok everyone, I'm looking to chop up my bike again and make it a bit simpler and more fun to ride.

I've ridden it in it's current configuration for a couple years now. Here's some pics of it now:







Things I like about the bike:

The front end
Exhaust
Wide rear tire
Gas tank

Things I no longer want on the bike:

Air-ride system
Jackshaft
Too long wheelbase
Wide handlebars
Headlight
Forward controls
dropseat

I've really enjoyed riding this bike as is for a long time, I've taken it to a few shows and gotten some good feedback, but I think it's time for a change. I've done the air-ride thing and now I'm over it. It just takes too long to fill the tank in the mornings, there's endless air-leaks to track down with all the vibrations, but most importantly the charging system on the bike is not strong enough to completely overcome the drain when the compressor is running, so while it's airing up the tank it'll start missing on one cylinder, and this problem is compounded when the bike is cold. It doesn't sound like that big of a deal, and it wasn't too bad for a long time, but I'm tired of it now. I just want to jump on the bike and go.

So here's the plan- I want to make the bike still cool, but with a different look, more upright riding position and just a more sporty ride overall.
I'm going to cut the back half of the frame off, try to use most of the existing swingarm as the rear section and just make it a traditional hardtail frame, no dropseat this time. Handlebars will be Mike's XS superbike bars, the guy I got them from is shipping them now, but here's a pic:



Sorry to Twinsarehot, I stole your pic :)

The current handlebars will get cut off at the fork tubes, and the headlight mount will remain, although it'll get modified to accept a different headlight, This awesome yellow lens 6v studebaker lamp with peeling chrome ;D I just need to buy a voltage reducer to run it.

The bike will be shortened by almost a foot, the bars will be higher, I'll probably switch to mid-controls and this time I'll have a sprung seat so people will shut up about it. Overall my goal is to make the bike a lot more fun to ride, not as much of a cruiser. More responsive for cornering, ect...

After a couple hours work today here's how the bike currently sits:





I'll get to chopping the frame tomorrow. No turning back now! Thanks for coming with me on this latest journey. I'm really hoping to complete this rebuild in under a month. Much unlike my usual build times.
Sky
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  #2  
Old 08-03-2010, 03:42 AM
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Chop Chop.... seems a bit shorter now!





Here's my headlight and the headlight mount with the bars cut off. I still need to remake the part where the headlight attaches as it's a different style than the other light



Really enjoying playing with my new lathe, turned down some tube to fit perfectly inside the other to make some frame slugs:



The swingarm has all the stuff I don't need anymore chopped off and is ready to weld back on. Here are a couple pics of it in its planned location:





Super happy with it so far, and I'm glad it's moving along quickly as well. I kind of have a deadline for finishing it, my brother in law is coming to visit with his bike on the 21st, so I'm really hoping to have this done in time to ride with him.

Thanks again for looking
Sky
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Old 08-08-2010, 02:23 AM
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Progress!

Got my handlebars in, they are perfect just what I wanted!



I also got some springs for the seat, just cheapo 3" springs



I'm hoping to have those mounted tomorrow. To what you ask? My new seat:



Haha, I know what you're thinking. Truth is this bike will still only be ridden about 60 miles at a time, and I'm thinking that a combination of the gel seat and the springs will be comfortable enough. Anything has to be better than what I had right? :)

Got the frame together and welded up as well:







I've got to cut some new wheel spacers to recenter the rear wheel, but man I'm really happy with how this is looking right now.

Plan for tomorrow is to get my pegs mounted, center rear wheel, remount rear lower fender mount, Cut down rear fender, make new shorter thicker fender struts, mount seat. I'll never actually get all that stuff done, but I can dream right.....

Thanks for coming along
Sky
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Old 08-08-2010, 08:43 PM
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CAPTAIN CNC CAPTAIN CNC is offline
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Lookin good Sky. I'm a watchin yer build. Wish i had a bike to customize per my likeing. I've got too many projects in limbo already. So you workin on both of yours at once or is the other on hold for now?
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Old 08-09-2010, 02:59 AM
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It's on hold for the time being. I was pushing too hard to try and get it started and was starting to cut corners. I don't want to do that, so I'm taking a step back to regroup.

More pics....

Didn't get a whole lot accomplished today, but it's coming together. I did get the pegs mounted:



I realized that I shouldn't go with mids because it'd just be too short for my size. So I just redid the existing pegs.

I got started on my seat mounting, this looks like angle iron, but is in fact two pieces of flat stock, I used what I had around :)



Front mounting point getting there:



Tossed the engine back in to check alignment and such, some quick mockup pics:







I need some opinions here though guys, I'm pondering leaving the rear fender the length it is instead of cutting it down. What do you think?

Also, eagle eyed people will recognize the front seat mounts as being my old fender struts haha,

A couple pics of me on the bike as well:





I'm feeling good about the deadline right now, lots and lots of little stuff to iron out, but still I think I can make it!

Thanks for looking
Sky
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  #6  
Old 08-15-2010, 01:19 AM
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Ok everyone, time for some new photos. Worked a bunch today and got a lot done.

First and most important I got my kickstand setup. It was a bittersweet moment to put a kickstand on this bike :)





Also, since i got pretty much universal hate on my seat choice I went a different way :) I cut down my original seat pan and used that instead. Also I got the headlight mounted and some wiring stuff out of the way. Also I got the chain cut and installed. Basically there's a lot of little stuff left to do. the only real fab left is to make the new fender struts. So here's some pictures of the bike almost finished:



I love my headlight :)







Thanks for looking, and right now it looks like I'm going to make my deadline of riding it by next saturday. Actually I'm hoping to have it finished Thursday night so I can do some shakedown rides before Sat.
Sky
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Old 09-02-2010, 04:15 PM
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Right you are guys, I definitely need to update this thread.

Here's the chronicle from where I last left off. I tossed some spray paint on the bike to cover the bare metal. put the remainder of the bike together and it was having running issues. Found the condenser was not grounded properly, then there was a piece of rubber stuck in the crossover tubes between the carbs. Got the bike together and running properly the Sat. morning that my brother in law showed up.

We got to go for a couple rides Sat. here's a few shots of the bike that day.











Sunday I got to go for another ride out the a local golf course to play a round, and about a mile from the course my bike backfired then all the lights went out and it started running on one cylinder again. Fortunately my dad was able to come down and we loaded the bike into the back of my pickup, I said forget it I'll look at it later and played some golf.

When I got time to look at it I found the battery bone dry- checked the charging voltage and it was around 17V! Oops. I never really checked on the battery water level, I think it got completely dried out and shorted everything else out. I got another battery to see if there were any more problems and sure enough it was still running on one cylinder. I pulled the carb back apart on the left side some sort of filing was stuck dead center in my pilot jet. The rest of the carb was spotless. Now the bike starts first kick every single time, even dead cold.

I got a new regulator for the bike, but it's a little bit different style so I had to rewire things a bit. That's where I'm at right now, just finishing up the rewire and put my new battery in. Should be really ready to ride this weekend. I hope.
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Old 09-28-2010, 11:56 PM
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Ok little update on this bike:

I moved the seat back about four inches and have been riding it, but it just looks way too ordinary and honestly I'm not loving it. So yesterday I had a little brainstorm and decided to steal the clip ons from my other bike project and slap them on this bike, here's the results, I happen to love it!

Definitely makes you lean over more, but I never rode this thing long distance anyway LOL.







riding position pic:







Sorry for the progressively darker pictures, best I could do right now.

The bars from this bike will probably go on my turbo sportbike build. Maybe they'll fit that one better!

Thanks for looking
Sky

Last edited by Yamaha_chop; 09-29-2010 at 12:00 AM.
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  #9  
Old 09-29-2010, 12:31 AM
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i like the way the clip-ons look... and the seat looks better farther back. damn nice ride... great job!

wish i could do something like this with my R1...
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Old 09-29-2010, 04:01 PM
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i might have missed it... but,this is an XS 650... right?
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  #11  
Old 09-29-2010, 04:21 PM
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Yessir
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Old 09-29-2010, 04:23 PM
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Your thread deserves a lot more attention than what we have been giving it. The build looks great. I will give you 5 stars.

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Old 09-29-2010, 09:23 PM
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Thanks for the compliment I really appreciate it!
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Old 10-02-2010, 07:10 PM
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Toreadorranger Toreadorranger is offline
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What are you doing with the old bars? Want to sell them?
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Old 10-14-2010, 06:44 PM
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i just picked up a KZ550 to chop... and i was thinking the same thing Toreadorranger.
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Old 10-15-2010, 12:21 AM
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They are only $30 from MikesXS but I think Im going to cut up my KZ400 bars before I buy them.
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Old 10-15-2010, 08:20 AM
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took a small search, but i found them Tore... thanks.
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