New member starting a project 650

[johnnyc14]

I just picked up a 650SE and have decided to do it up in street tracker style.
I bought a used front wheel from a 80 XS110 to use as the rear for my project. I am going to build my own mounts as I have a lathe and milling machine in my garage. I have started with the sprocket side, I machined a sprocket starting with a 530 sprocket blank purchased from a local supplier. I used 12mm dowel pins between the teeth to mount it in the lathe and milling chucks. I bored the center to 2.516" to be the same size and the brake rotor mount on the wheel. Then added the bolt holes using an 80mm center hole circle and 6 decorative holes to resemble the original sprocket. Then I coated the exposed bare metal areas with a black oxide finish. I machined a sprocket spacer from a 4.5" round of aluminum I bought a the local metal supplier.

Here are the plans I drew to plan the machning of the spacers.

John

 

[tonyc]

Johnnyc you have true talent and craftsmanship.

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[fredintoon]

Hi John,
FYI, an XS11 cast front wheel is identical to an XS650 cast front wheel.
And I hate to use the expression but aren't you re-inventing the wheel?
There's lotsa guys already put XS650 cast front wheels at the back of
their street-tracker builds.
Hit the search button to see how they did it.

 

[Vansnxtweek]

Holy kamolee this is cool. Can't wait to show this thread to my friend, we are both fascinated by metal working skills like that. Excited to see more!

 

[Dieselchanic]

Most guys use a kit to out a front wheel on the back. A kit that's no longer available to my understanding, and would have been too expensive to buy if you've got the skills to build it. So I think it's totally cool what you're doing! Keep it up, I'm curious to see the result.

 

[scabber]

Welcome. Looks like you are off to a good start. Nice to have the machinery and skills for the build. Some pictures of the bike would be great. Keep posting you progress.

 

[johnnyc14]

Thanks for your comments guys.
Fred, I bought the XS11 wheel knowing it is the same as a 650 wheel. As a bonus it came with 2 slotted brake rotors. I am building the parts because it's fun and testing my skills with the machining equipment.

I will keep you updated with my progress. Work is getting in the way of the bike building fun!

 

[rahndo]

Jim Henry does the kit for $160 and shipping. Just need to be on his list.

 

[johnnyc14]

That's a great deal, it's a lot of work!

John

 

[torider]

Nice fabrication work! Welcome to the forum by the way.

 

[johnnyc14]

Over the last few days I have finished machining all the parts for my 19" rear wheel conversion. It will use three 6204 bearings, the 2 in the original locations in the wheel and a third in the sprocket side spacer to help deal with the extra load on that side of the wheel. Here is a pic of the sprocket and rotor spacers and the one I machined to go between to 2 wheel bearings.

I warmed up the spacer with my heat gun to 175 deg F and the bearing just dropped right in.

I machined another spacer to go between the left wheel bearing and the sprocket spacer bearing.

Here is the wheel assembly assembled to mock up in the frame.

I clamped a straight lenght of 1/2" square aluminum to the front sprocket in order to space the wheel correctly for chain alignment then measured and machined the 2 outer spacers from stainless steel.

I mounted the front wheel to check alignment front to rear with 2 straight lengths of lumber and it turned out spot on.

Now that the machine work is done I can pull the engine and get at the rest of the project.

John

 

[Vansnxtweek]

Looking good!!

 

[TwoManyXS1Bs]

Excellent write-up and supporting pics/drawings. Will be quite handy for others.
Here's another lathe project for you: http://www.xs650.com/forum/showthread.php?t=32267

 

[tonyc]

Great work.

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[fredintoon]

Hi JC14,
is that a mill to the right of the lathe's tailstock shown in the photo?
You could use it to slot the rear brake rotor to match the XS11 rotors.
Should be easier than drilling them like I did, that rotor material is as tough as old boots.

 

[johnnyc14]

Thanks guys. Last year I bought a used 14 X 40" lathe and a new small milling machine and have been having a lot fun with them ever since. I do plan to slot that rotor Fred. Since the slots are angled (not vertical or horizontal) I have some thinking to do before I start that project.

Here are the machines in their clean state, not how they look right now!

John

 

[scabber]

The aluminum mags some years are tube type others are marked tubeless. Nice job on the sprocket adapter like the extra bearing incorporated in your design. The disc brake looks better than the drum brake. That push rod project is worth doing. Don't let work stop the build.

 

[fredintoon]

- - - Since the slots are angled (not vertical or horizontal) I have some thinking to do before I start that project. - - -

Hi John,
if you have a rotating table for your mill it's easy to cut the slots.
Otherwise use the 3-jaw chuck shown in your #1 post photo #6.
One setting gets you 4 slots, rotate the disk on the chuck 30º then 30º again to get 8 more.

 

[johnnyc14]

The used 19 inch wheel I bought came with 2 slotted 300mm front brake rotors. The original single front 300mm rotor and the rear 270mm rotor are not slotted. I plan to use dual front brake rotors and they will be the slotted ones so I decided to match the slot pattern from the front rotors on the rear one. I mocked up the first slot and spot drilled the center and both ends of the slot to get locations on the DRO. With the rotor mounted in an extra hub I made and in my Vertex super spacer I copied the location at 60 degree spacing around the rotor and drilled all the holes to 8mm the slotted them with a 1/4" end mill. The stainless rotors are pretty hard so it was slow going but turned out well. After the slotting I mounted it in the lathe and use 320 grit sand paper to polish it up a bit.

John

 

[Vansnxtweek]

This is so sweet. Did it take an extremely slow speed to drill through cleanly?