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Vintage Bobber Build Thread

Discussion in 'The Garage' started by phil1rowe4, Feb 23, 2016.

  1. Have been busy working on the bobber build since the last post. The seat foam has been shaped and made a patchwork leather seat cover for it.
    IMG_20181103_232110.jpg IMG_20181103_232244_1.jpg IMG_20181104_180024.jpg IMG_20181104_180123.jpg
    Scripto VU and GLJ like this.
  2. Have also made some custom bars, painted the external springs and cups, mounted the guages and made the headlight mount. Also made the forward footpeg mounts.

    IMG_20181129_073442.jpg IMG_20181128_184550.jpg IMG_20181223_094505.jpg
    Scripto VU, Mailman, GLJ and 3 others like this.
  3. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi phil,
    the Scottish say "Bairns and fools shouldnae see a boat half-built."
    But I do trust you will fit either a fork-brace or a front fender to your build.
    Otherwise you'll be doing a Mr. Wobblyarse as you ride.
    Superjet likes this.
  4. Hi Fred,
    lol, the Aussie registration rules wouldn't let me have a bike with no mudguards/fenders even if I wanted to, so it's definitely getting guards.

    Part of the vintage styling I'm aiming towards also includes having fairly full guards and I have some universal fenders that I'll be modifying to fit. The rear has trimmed to length but the front hasn't yet.

    gggGary and GLJ like this.
  5. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    I'm stuck on fenders right now!!!!! Want to see how you do those.

  6. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi phil,
    thing is, the XS650 front fork really needs a fork brace to help it work nice.
    The stock front mudguard's massive centre-section did that job OK so make sure that whatever you put there instead does it too.
    gggGary and Superjet like this.
  7. hotdog

    hotdog XS650 Guru

    Looking good so far Phil
    phil1rowe4 likes this.
  8. Thanks Hotdog.

    I've made a start on the mudguards. I started with universal guards meant to suit 19" wheels but found that to match the curve of the tyres meant the guards had to sit several inches off the tyres. I hate it when guards don't match the curve of the tyre and wanted them to sit less than an inch off the tyre, so I have to change the radius of the guards.

    To start I cut off the folded edges of the guards, and then used a metal shrinker to pinch the edges of the guards which reduces the radius of the guard. Unfortunately the shrinker marks the metal and introduces little kinks, so these have to be hammered and dollied out and then file finished. Very time consuming! It would be better if I had an English wheel, but I don't. Fortunately I do have lots of time.
    Radius is just wrong.
    Cut off the rolled edges.
    Metal shrinking tool.
    Working out the kinks.
    Trial fit.
    Stardust83, Mailman, lakeview and 3 others like this.
  9. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Very cool, following...
  10. Front guard mount (including fork brace) now almost done. Tried to take some styling cues from the xs1 with the rear stay.

    Hopefully I can get some time tomorrow to do some more work on the rear guard and mounts.
    Once the guard and exhaust mounts are done, I can blast the frame and paint it. Awaiting some parts from Heidon to allow the engine rebuild to begin. Given this bike and engine started as a bunch of loose bits, it's come a long way but still lots to do!
  11. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi phil,
    a "budget" English Wheel is reasonably affordable.
    From what I remember of my 3 month apprentice time in the sheetmetal shop
    you will need the lots of time to learn how to drive the bastard.
    It ain't as easy as it looks.
  12. I've finally got the rear guard reshaped and the guard supports fabricated. The guards really set the look of the bike so were important to get right.
    Final engine parts have now arrived so I will start on the engine rebuild soon.
    IMG_20190216_173213.jpg IMG_20190216_173312.jpg
  13. MrBultaco

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

    This is getting good............:popcorn:
  14. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    How did you attach the struts to the fenders?
  15. Welded some tabs to the struts and bolted through the guard. Dome head stainless bolt from underneath with brass dome head nuts outside. I'm using brass dome nuts in several
    places as part of the vintage theme.
    Mailman likes this.
  16. I have been working on the frame recently finishing all the new tabs for rear indicators, exhaust, regulator, coils etc. Then a bit of clean up of all the nicks, bumps and grinding marks from old brackets before sand blasting the frame in the back yard. Hot, messy job! Swingarm has had 2 coats and is looking good. Frame should get painted this week.
    IMG_20190307_193711.jpg FB_IMG_1552261845891.jpg
  17. timbeck

    timbeck XS650 Junkie XS650.com Supporter

    Phil- I'm loving this build, great work.
    phil1rowe4 likes this.
  18. Thanks Tim,

    Here's the frame after the first top coat. The frame was sand blasted, treated with phospheric acid, etch primed and then will have several top coats. I'm using a satin black.
    Getting a bit excited now to have a finished rolling chassis and start bolting bits on.
    gggGary, timbeck and Superjet like this.
  19. Hey guys,
    Been busy rebuilding the engine and just about finished. Just have to paint the side covers, top end all done. I must say the resources, knowledge and info on this site is priceless. Thanks to all who have contibuted technical articles.
    IMG_20190322_193226.jpg IMG_20190322_193325.jpg IMG_20190316_113003.jpg
    TwoManyXS1Bs, MrBultaco, Jim and 4 others like this.
  20. Hey guys,
    Engine all done now and back in the frame. Still lots to do.
    IMG_20190412_172954.jpg IMG_20190412_173148.jpg IMG_20190412_173042.jpg

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