Paul, yer da man! I'll watch closely to see how this works out...
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UK Board Tracker Build Thread
- Thread starter Paulrxs650
- Start date
Paulrxs650
XS650 Enthusiast
A little more fiddly work done today while I await the frame. I took the original headstock off the frame and tidied it up. While I had it on the bench, I remembered how awkward it was to drift out the bottom shell for the bearing from other builds. So, I filed two small channels to allow me to drift it out easy at tear down.
I also ground off the bottom engine mounts and side stand mount off the old frame, just in case I can use them on the new frame.
I also ground off the bottom engine mounts and side stand mount off the old frame, just in case I can use them on the new frame.
Paulrxs650
XS650 Enthusiast
Still passing the time til the frame arrives. Hopefully that should be soon, as David at Voodoo Vintage says it's now complete and will ship this week. Jerry from Heiden is also shipping my order this week. Plus I've got a set of R1 2014 forks coming from the states too. What did arrive this week was a nice new PMA, exhaust tubing and these lovely brand new 6 pot calipers
I also decided to get a head start on the exhausts, particularly the clamps. I didn't want to use the originals as they are quite bulky and heavy. So I opted for The flat plate ones the come with the TC Bros kit and detailed them with a rat tail file
Finished them of on a wire wheel, ready for chroming / ceramic coating along with the exhaust once it's built
I also decided to get a head start on the exhausts, particularly the clamps. I didn't want to use the originals as they are quite bulky and heavy. So I opted for The flat plate ones the come with the TC Bros kit and detailed them with a rat tail file
Finished them of on a wire wheel, ready for chroming / ceramic coating along with the exhaust once it's built
Paulrxs650
XS650 Enthusiast
It's like Christmas morning! Can't wait to get in the workshop tomorrow.
scabber
XS650 Guru
Looks like the build is going good. Frame, front end and brakes will keep you busy.
Paulrxs650
XS650 Enthusiast
Yes, I can now get underway in earnest. My Heiden delivery comes on Monday, so I'll have all my bits and bobs.
Off in the workshop I go !
Off in the workshop I go !
Paulrxs650
XS650 Enthusiast
A very productive day in the workshop today! I got the frame on the bench and trued up level and straight. I then got the headstock located trued and tacked on. Popped the forks in to check stance, ride height etc. All looks good, albeit I did have to raise the front of the frame slightly. However, I think I can lose a good half inch or so in adjustment and there'll be another inch or so, when the suspension compresses. Just leaving everything tacked for now, just in case.
I popped the engine in to get a feel for where it will sit and I'm pretty happy with how it fits. I had already removed the original bottom mounts from the old frame, so I used them along with some 10mm stainless bar, to tack to the frame. The frame is slightly wider than the original, so I'll thread either end of the bar and machine some spacers later
When I fitted the calipers, I noticed that due to the way they mount, there is not a lot of room left between them. In fact I think they mount back to front, as the rather nice aluminium piston caps are on the inside. I checked and they're mounted like that on the new bikes. Anyway, laced up a wheel to the old hub and popped it in. Indeed there is interference with the spokes. However, there is plenty of meat on the inside of the calipers, so I may be able to machine them down. Once I get some 22mm bearings, I'll mock it up properly and work it out.
Tomorrow I'll work more on the engine mounts. Due to the tank I'll be running, I'm not going to use a top mount on this bike.
I popped the engine in to get a feel for where it will sit and I'm pretty happy with how it fits. I had already removed the original bottom mounts from the old frame, so I used them along with some 10mm stainless bar, to tack to the frame. The frame is slightly wider than the original, so I'll thread either end of the bar and machine some spacers later
When I fitted the calipers, I noticed that due to the way they mount, there is not a lot of room left between them. In fact I think they mount back to front, as the rather nice aluminium piston caps are on the inside. I checked and they're mounted like that on the new bikes. Anyway, laced up a wheel to the old hub and popped it in. Indeed there is interference with the spokes. However, there is plenty of meat on the inside of the calipers, so I may be able to machine them down. Once I get some 22mm bearings, I'll mock it up properly and work it out.
Tomorrow I'll work more on the engine mounts. Due to the tank I'll be running, I'm not going to use a top mount on this bike.
Paulrxs650
XS650 Enthusiast
A little more progress today. I trimmed down the headstock and stem, then machined down the top collet, now that I'm happy with the set up of the steering.
I decided to start on the engine mounts. However, once you start thinking about them, they become a right pain in the back side. Obviously, we need solid engine mounts but I'm very keen not to have hideous bracketry sprouting from the bike. I'm already omitting the top mount, so need to ensure that the others will be up to the task. So, I mocked up a few ideas in card and plumbed for the below that I made out of some 6mm steel.
I decided to start on the engine mounts. However, once you start thinking about them, they become a right pain in the back side. Obviously, we need solid engine mounts but I'm very keen not to have hideous bracketry sprouting from the bike. I'm already omitting the top mount, so need to ensure that the others will be up to the task. So, I mocked up a few ideas in card and plumbed for the below that I made out of some 6mm steel.
Paulrxs650
XS650 Enthusiast
Got my Heiden delivery today. Everything seems to be good but we'll learn more once we're up and running.
Still mulling over what I want to do with the upper rear mount. I've asked David at Voodoo what they normally prescribe
Still mulling over what I want to do with the upper rear mount. I've asked David at Voodoo what they normally prescribe
Airwolfie
XS650 Guru
Very pro dude! Looks good!
Still want one of them sexy frames!
Still want one of them sexy frames!
Paulrxs650
XS650 Enthusiast
Cheers Airwolfie! Yeah, the frame is awesome- a work of art!
Airwolfie
XS650 Guru
I know! That's why I want one!! Just can't afford it now i got the little bambini!
Paulrxs650
XS650 Enthusiast
Hey congrats man! You'll just have to be patient 
Airwolfie
XS650 Guru
Hey congrats man! You'll just have to be patient
Thanks! she's 15 moths old already!! Quite a handful, but so much joy in a little bundle! Wouldn't trade it for the world!
That's quite a few, Airwolfie.
Didn't much care for them myself. Tasted like dust...
Paulrxs650
XS650 Enthusiast
Talking to David at Voodoo, he says that they omit the top rear and head engine mounts without any issue. I believe Yamaha designed the stock set up with the engine as a stressed member. So the new frame doesn't require that engine as a stressed asset. So, I am considering going for three mounts only, albeit fairly robust ones. Some more time on this is required I think.
Paulrxs650
XS650 Enthusiast
Just a little bit of work done this weekend. I got some 22x47x14 Bearings and popped them in. Offering the calipers up showed I did indeed have a interference problem with the spokes. So, I machined down the inside face of the calipers by 1.5mm and chamfered off the edges to get the clearance required.
While I was at it, I machined the highlights of the outer face to add a little bit of definition
Roughly laced the rear wheel up, just to get an idea of the overall stance
While I was at it, I machined the highlights of the outer face to add a little bit of definition
Roughly laced the rear wheel up, just to get an idea of the overall stance
Ditto! Ay, caramba!
Paulrxs650
XS650 Enthusiast
Thanks guys. Two many, I got those bearing and bushes. Neither will workm afraid. There's just not enough metal on the case. However! There is a local company I've found that make bearings, so I'm going to pop in and see what they can do.
I've got a whole weekend in the workshop this weekend so we'll see where we get to
I've got a whole weekend in the workshop this weekend so we'll see where we get to
