New to XS650’s (and Yamaha) Build

Thanks guys! I’ve been working on mock ups for a paint scheme, I’m thinking of a take off on the DT3 tank decals, but with gold pinstripes instead of white. Also throwing around the idea of incorporating the tuning fork raised emblems rather than the Yamaha lettering.
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The brown seat and grips should go good with the metallic green and I might pick up a brass engine bolt kit. Early stages, but I’m trying to get something in mind before I start stripping the tank down.
 
Shortened the new dirt bike bars about 1 1/2” and finished the mount bracket for seat latch. Soon as the weather is nice enough to work outside I’ll get the welder fired up and start tacking on all these bits and fixing the PO slop. Probably stronger than the tape I’ve been using :lmao:
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Shot of it all together
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Started cleaning up the back end for the hoop. The PO just tacked the hoop onto the back and it didn’t look right. It was too far from the back of the seat and was also crooked. I ordered a new hoop and will be welding it on properly. To start I chopped the back off and fitted the solid slugs, the new hoop is supposed to arrive this week.
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More fun with random bolts I find in my garage! The bar end mirrors I had for the bike weren’t going to work with the new aluminum bars. I tried making a different rubber insert but it just wouldn’t tighten down enough. So I went with another solution. The ID of the bars is 1/2” and I just happened to have a new 1/2” Dia bolt...so I made some new inserts for either end of the bars.
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From there I drilled a hole through the centre (well...kind of the centre - still perfecting my drill press technique :lmao:)
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I tapped these holes for some cap head bolts I had. I then inserted them into the bars and drilled a vertical hole down through the bars and halfway through the insert. That hole was tapped to accept some set screws I had. The set screws were tightened down flush with the bars and I did a bit of sanding to make sure they were smooth and wouldn’t interfere with the throttle. They should stop the inserts from pulling out.
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Everything tightens down nice and snug and with a little locktite during final assembly should hopefully keep anything from vibrating loose (hopefully).
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Looking good Hoser!
Hint to center drill in a drill press
#1 chuck your piece in the drill chuck, clamp the drill in the vice.
#2 use a center drill to start.
I had seen this tip before but the chuck on my little bench top drill press didn't open wide enough to give it a try. I'll give it a shot next time I have to drill out something a little smaller :thumbsup:
 
I had an old front fender kicking around (I think from a CX500) that I am going to try and make work. Chopped it down and smoothed it all out. The holes are from drilling out spot welds to remove it from the inner mounting bracket. I’m either going to try and rework the insides of the XS fender to mount or build something myself.
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Finished fitting the new hoop and made a couple small filler pieces to patch the frame.
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I’m going to bolt the fender into a threaded lug welded to the bottom of the hoop with a support for the tail light under the fender. The fender will end up stick out a couple more inches than this, I was just using one of the many already drilled holes. If I can’t patch it up I’ll have to look for another one to use
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Got things welded up and fitted. Pretty happy with how it came together despite the fact I’m not a great welder. Once I finish sanding and get it painted I think I’ll be satisfied.
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