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Large Spine Frame XS650 / Egli / Rau / Cafe Racer

Discussion in 'The Garage' started by rehar, Dec 18, 2017.

  1. Busy summer. Progress on the new subframe is making steady and slow.

    Here are some pics.

    1 IMG_1678.JPG 2 IMG_1680.JPG 3 IMG_1681.JPG

    Fish-mouthing tubes, great way to consume a lot of time.
    4 IMG_1688.JPG 5 IMG_1686.JPG 6 IMG_1689.JPG 7 IMG_1692.JPG
    Temporary cross tube, just to align left and right sides.
    8 IMG_2028.JPG 9 IMG_2030.JPG
    11 IMG_2035.JPG 12 IMG_2040.JPG 13 IMG_2043.JPG 14 IMG_2044.JPG 15 IMG_2050.JPG
    16 IMG_2096.JPG 17 IMG_2099.JPG 18 IMG_2105.JPG 19 IMG_2101.JPG 20 IMG_2102.JPG 21 IMG_2109.JPG
    Top part was the original plate bracket. The plate had a nice fatigue crack after just a few miles, perfectly aligned with the bottom edge. This will provide more support. Will use some foam padding and perhaps some 3M VHB in strategic locations.
    22 IMG_2141.JPG 23 IMG_2142.JPG 24 IMG_2144.JPG 25 IMG_2145.JPG
    Thought I would try something new. Fish-mouth on one end, flattened, formed and slightly bent on the other end.
    Very fast and I'm happy with the end result.
    26 IMG_2155.JPG 28 IMG_2160.JPG 29 IMG_2162.JPG 30 IMG_2163.JPG

    Second to last photo, you can see the new seat mounts at the back. 4 screws all together. Not as quick to release as the previous thumb screw (painful actually) - but allows me to keep rubber mounts to the seat and tucks the frame rails up underneath the seat lip.

    Turn signal hangers tomorrow. Then some clean up before paint and new electric tray.
     
    Last edited: Sep 1, 2019
  2. Jack

    Jack XS650 Junkie

    Try to contact mrriggs at mrriggs@gofastforless.com Don't know if he'll do the rephase for you but give it a shot. He's a engineer like you,real sharp. The problem with rephasing is ignition but he also has a solution for that which you'd have no problems making with your skills. Also falcon cranks might be an option. You want the engine rebuilt contact Hoos Racing XS650.
    Your XS is the best custom build I've ever seen, your skill level is over the charts:bow2:
     
  3. I don't think I can live up to such praise, but thank you. And thanks for the tips, I'll explore all options.
     
    Last edited: Sep 5, 2019
  4. Wordman

    Wordman XS650 Enthusiast

    Another rephased ignition solution: https://yambits.co.uk/xs650-newtronics-electronic-ignition-system-rephased-crank-p-23732.html
     
  5. wannabridin

    wannabridin XS650 Junkie

  6. Jack

    Jack XS650 Junkie

    back about 12 years ago, maybe longer Bob Bertaunt was using them on his rephase and two of them took a dump back to back, that's when he modified the points system to 277. Whether or not they've worked the bugs out
    would be a concern. I bought one and immediately sold it. The box is real flimsy ,you can shake it and hear the electronic panel moving,not a good sign of workmanship in keeping the components
    stationary while riding,along with the vibes. I have all the details in modifying the points plate, I copied them knowing that 650motorcycles would'nt last long with the new ownership and I was right. A lot good information and bike pictures are lost forever now.
     
    Last edited: Sep 7, 2019
    JAX71224 likes this.
  7. Wordman

    Wordman XS650 Enthusiast

    To be fair, that was 12 years ago. I'll open mine up and have a look inside.
     
  8. Devil's in the details... or am I just spending too much time on this... Hmmm... :shrug:

    I'm going to switch to a longer, larger diameter megaphone, much better sound. But - it's heavier and the CG is much further back. So I will have to use a more traditional pipe hanger from the sub-frame, instead of the mount off the rear foot peg.
    Basic Concept:

    1 pipe hanger 1.JPG 1 pipe hanger 2.JPG
    From a square tube:
    2 Tabs From a 1 inch tube IMG_2209.JPG 2 Tabs IMG_2210.JPG
    The Blue bits need to be fabricated:
    3 pipe hanger blue bits will need to be fabbed.JPG 3 pipe hanger erhrtg.JPG
    This round piece, when done should be much thinner than in this photo. The chuck on my lathe needs about two teeth to hold it straight.
    So, make it oversized and machine /turn it later (I'll refer to this piece as the bung):
    4 a want smaller, but small lathe IMG_2212.JPG
    Need to make a small chamfer for welding the tube onto the bung.
    4 b small lathe Can barely make chamfer for welding IMG_2215.JPG
    OK, using some parallel bars, I was able to space out and hole the bung pretty straight, enough to allow the bit to create the feature.
    4 c small lathe squared up Parallel bars IMG_2216.JPG 4 d small lathe IMG_2217.JPG
    Bits are ready to weld... Did I mention that I am NOT a good welder?!!
    5 ready for welding IMG_2220.JPG 5 s after welding IMG_2222.JPG
    35mm long, need to trim down to around 25. Trim off a little on both ends. With the extra tube material, I can now hold it pretty easily in the lathe...
    5 ss 35mm needs trimming after IMG_2223.JPG
    25 VS 35mm:
    7 trimmed IMG_2227.JPG
    Done for today:
    8 IMG_2228.JPG 9 Done for the day IMG_2229.JPG 9 Done for the day IMG_2230.JPG
     
    TwoManyXS1Bs and Jim like this.
  9. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Man, I just *love* those CAD drawings...
     
    MrBultaco and Jim like this.
  10. Jack

    Jack XS650 Junkie

    One of the best 2 into 1 xs exhaust note I've heard came from a mounted Yoshimura.
     
  11. Still considering exhaust hanger options and dinking around with various tube forming methods...

    Here is a quick test tonight.
    Some random steel bits (about .4" thick), cut a notch in one of them.
    3.jpg 4.jpg 5.jpg
    Load sample tube (on my 12ton press).
    6.jpg
    I didn't get the tube "V" centered. Gotta figure out how to align it better and probably should have a rounded end to the V.
    7.jpg 8.jpg 9.jpg 10.jpg

    (Not perfectly flat. A bit nervous, didn't want to add too much pressure. Heard horror stories of these cheap press plates catastrophically breaking when overloaded.)
     
    TwoManyXS1Bs and Jim like this.
  12. And another, simplest method...

    brackets front.JPG brackets left.JPG brackets comparison.JPG

    Maybe less intrusive on the inside of my leg...
     
  13. Got a little bit of work done this weekend.

    Got the mount welded on to the new 18" Megaphone.
    IMG_2255.JPG IMG_2256.JPG
    Got the hanger tabs on to the subframe and the pipe hanger done.
    Here are some pics of the new rear end. (Still need to redo the electronics tray, some more clean up, paint...)
    IMG_2269.JPG IMG_2270b.jpg IMG_2269.JPG IMG_2271.JPG IMG_2272.jpg IMG_2273.jpg
     
    gggGary, TwoManyXS1Bs and Jim like this.
  14. MrBultaco

    MrBultaco it ran before being parked XS650.com Supporter Top Contributor

    648
    1,999
    143
    Colorado
    Hey man, get on this thread and accept your nomination for the calendar....

    2020 XS650 CALENDAR *OFFICIAL* THREAD - NOMINATIONS
     
    TwoManyXS1Bs and Jim like this.
  15. Thanks! I had no idea this had already started!
     
    gggGary and Jim like this.
  16. XSevive

    XSevive XS650 Enthusiast

    Hi , great build, ,here in australia that would never be able to be put on the road, whats the laws for that stuff over there. ?
     
    gggGary likes this.
  17. One thing with "OLD" California Motorcycle titles: They only have the VIN number for the frame. So the engine and frame should match, but there are no legal documentation for this... Gray area...

    Warning, non-XS650 pics below...

    I engine swapped a Ducati ST3 in to a 996 chassis. I went through the troubles of updating the title so everything matched. I had to show receipts for everything. DMV inspected the frame and scrutinized it for non-mass production welding... And the big item that stopped me was a vin sticker was missing from the stock seat, that was supposed to match the frame. I borrowed a seat from a friend, bastardized it onto the bike and although the numbers didn't match I got passed inspection second time.
    WP_000223.jpg WP_000226.jpg

    Legally, I can get what is called a Special Construction title (SPCN) in California. I believe each state is different. Hearsay, is California will allow you to do ONE SPCN title ONCE per your life. (Brilliant!) I have done one SPCN already with an aluminum framed Ducati (frame was commissioned by Over Racing of Japan). The process is vague but basically you need to show receipts for all the major components so they have some evidence that you didn't steel the parts...
    OVleft.jpg OVright.jpg

    I have heard that some places are actually concerned with safety and actually have a process one would go through to ensure the vehicle was safe for the road. Aircraft have such a process. Wish they could do something like that.

    What are the guidelines in Australia?
     
  18. XSevive

    XSevive XS650 Enthusiast

    pretty strict, Officially you cant register anything that has had any modification,repair or damage whatsoever to the frame, eg a bent steering stop will write off a bike here, or a small dent in an alloy frame spar, crazy, but sells new bikes i guess.there are thousands of perfectly good bikes getting scrapped because of very minor defects that dont affect the integrity of the bike. you can have an engineer do a report on a modification but its not cheap, the only real way to do a custom is modify a registered bike and tell no-one.,to get mine registered wasnt hard though... i happen to live in a small country town so its a case of who you know,not what you know. LOL
     
    rehar likes this.
  19. Sounds very strict. I've seen some very cool and some very wild bikes from Australia. Makes me appreciate the challenge even more! I like your bike alot! Very cool! Can't wait to see it in the 2020 Calendar. Do you have a build thread or pics during the fab/modification work? I'd like to see more about fitting the swing arm and the rear shock mount/linkages. Old school bike, with more modern legs. :thumbsup:

    I used to live in Japan, there - they have a system of mandatory inspection (depending on the age and type of the vehicle) every 1, 2 or 3 years apart. Myself and the guys I hung around with all keep the stock parts and put it to stock condition for the inspection. I also heard of a loophole: an imported vehicle could be imported in nearly any condition of modification. So you could have a pretty heavily modified bike - totally legal - if it was imported in that condition. Some bikes were imported this way. There were also some players that would build the bike locally, then export and re-import the bike (at least via "paper trail"). Ahem...
     
    TwoManyXS1Bs likes this.

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