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79 Special II RestoCustom "Doomy"

Discussion in 'The Garage' started by Machine, Nov 22, 2019.

  1. Machine

    Machine Race the wind Top Contributor

    Here in the shop at work today I'm heading into the needed custom side covers. Fun that the 81 side covers I found are plastic so quickly sawing off a lot of the extra will go fast. From there I'll shape these into small custom shaped side covers which will attach to the battery box threaded holes which were for the airbox halves via posts
    :thumbsup:
    Test cut noise drew enough attention from coworkers that I'll have to be more stealthy :lmao:
    to be continued..
    -R
     

    Attached Files:

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  2. Machine

    Machine Race the wind Top Contributor

    20200227_055331.jpg Roughed out oversize quick & dirty at lunch while chewing lasagna lol. No safety Nazis present in the shop. Now they go home for more accurate shape marking.
    -R
    Edit Update, next morning ;)
    Yup slipping in more for those of you watching lol.. Yesterday at the vertical band saw here in the shop someone actually reported my lack of a holding fixture and that "safety concern" was brought up. See, working in a machine shop these days is not at all as it used to be. Plenty of puss rules now as the "dying art" of hands on manufacturing is truly in jeopardy.
    Anyway, the "Special" shape side covers are rather bulky and triangular compared to a "Standard" side cover so the goal here is with shaping, smalling, and visual illusion to create a more Standard like side cover. Last nights progress check confirmed there is plenty of extra plastic to whittle away. Shaping plastic body parts has been fun in my distant past so here goes more on the XS hang in there,
    I'll get there ;)
     

    Attached Files:

    Last edited: Feb 27, 2020
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  3. Machine

    Machine Race the wind Top Contributor

    20200227_055312.jpg
    And then there's the front fender to saw too.. question here. If I saw the fender on the vertical band saw, is the cut edge chrome going to flake, chip, or peel?
    -R
     
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  4. Brassneck

    Brassneck XS650 Guru

    I've not seen an OEM fender flake when cutting...assuming it's fairly trust free, for what that's worth...aftermarket is a different story. But, you may want to put some painters tape on the fender along the line where you're going to cut (cut down the middle of the tape)...that should help.
     
  5. Machine

    Machine Race the wind Top Contributor

    Nice Brassneck :thumbsup:
    This fender is pretty straight but not a "keeper" stock due to a little rust anyway. I have seen some shortened fender pics and think that is quite appropriate for this XS. Thanks -R
     
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  6. Machine

    Machine Race the wind Top Contributor

    20200227_172240.jpg
    At the end of the work week I'm walking out the door with parts to play with. The fender cut nicely (loudly) and I squared it up on the disc grinder and de burred it for fit checking for lengths. Hoping to put some descent radius's on the ends but not today.. And the side covers are much slimmer now and will be even smaller in the end.. starting to understand the custom builders habits..
    :thumbsup:-RT
     

    Attached Files:

  7. Raymondo

    Raymondo XS650 rider, fettler, setting out on a journey XS650.com Supporter Top Contributor

    Wot is that fender doing to that roll of paper towel?
     
  8. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Laughing Minions.gif
     
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  9. Machine

    Machine Race the wind Top Contributor

    20200228_172157.jpg
    Front fender mod will double as an air scoop!
    Front end "Lift" created by air forced thru the curve down of the fender will compensate for the added weight of the Left side brake components. This I'm sure of..
    :laughing:
     

    Attached Files:

  10. Machine

    Machine Race the wind Top Contributor

    Sorry guys, got no bike time today :thumbsdown:
     
  11. Machine

    Machine Race the wind Top Contributor

    Been about a week now not actually doing any mechanical work on the XS. I have however been gathering little bits such as the brake booster check valve (3 auto parts stores to locate1?) Jeez, a descent uncracked clutch worm, side cover badges. BTW , I need Chrome Silver Special tank badges still :whistle:
    But here is todays question ? After jumpering the black/blue wire to the black/yellow wire in the light RLU box, cant I just cut the whole bulky plug off the harness and cap the other wires instead of leaving it to stuff in there ?
     

    Attached Files:

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  12. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

  13. Machine

    Machine Race the wind Top Contributor

    Kansas City ? Dang, now why haven't those been seen anywhere in the PNW ?
    :yikes:
    Want to trade or sell em ?
     
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  14. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    You gave me a mirror for the SG. Just returnin' the favor. ;)
     
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  15. Machine

    Machine Race the wind Top Contributor

    So Cool !! Now that is XS650.com at its finest !
    Big Thank You Jim
    y80ss.jpg
     
  16. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    PM me your addy.
     
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  17. Machine

    Machine Race the wind Top Contributor

    20200304_113555.jpg
    Fixing all the little bits takes as much time as the the big deal stuff too
    ;)
    Little by little, getting closer.
    -R
     
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  18. Mailman

    Mailman Hardly a Guru Top Contributor

    Kindness is it’s own reward. :)
    “ We make a living by what we get. We make a life by what we give.” Winston Churchill
     
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  19. Machine

    Machine Race the wind Top Contributor

    Back acha Bob, seen your actions on here over the years as well
    ;)
     
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  20. 5twins

    5twins XS650 Guru Top Contributor

    18,792
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    I guess you could cut the plug off the RLU connection but it easily tucks down behind the battery box out of sight. There's lots of room there for it. Mine's even bulkier because I put the jumper wire in a matching plug, but it still fits fine .....

    [​IMG]
     
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