Monster Brat Build

quickj

quickj

XS650 Enthusiast
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I am going to start up a build thread for my XS650 bobber build using the Monster Craftsman Brat Kit. So I am calling it the "Monster Brat Build".

I have posted a few disjointed posts with some questions etc. So this will be my efforts to tie all of my stuff back into one place.

So Here goes;


The Starting Point.

I picked up a 1978 XS650 Special (type 2F0) with 12,732 miles at an on line auction for $225.00. It has a title, is not froze up, has great compression, but has not been started in many years. It was running when parked according to information I was able to get on it. It was extremely "Barn Fresh", very dirty, greasy, covered with who knows what, and had the ugliest seat and handlebar combination (mini apes?) that you could possibly get.

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I brought it home, and immediately started stripping it down to what I knew I would keep. Frame, motor, wheels, and forks. Not much else. I know that the common wisdom here would have been "Get it Started First" but I am impatient, and it was about 0 degrees in December when I picked it up.

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At that point, I loaded it in my truck, took it to the nearest self serv car wash, sprayed it with degreaser, and then scrubbed and pressure washed it.

Now let the fun begin...

Jim in Minnesota
 
I haven't really taken to many pictures to document the next steps of my build, so I will just say that I looked at many different routes as far as what I wanted to do. I thought maybe a tracker build, or cafe, or hardtail, etc. but I decided that I really need to keep the back end soft. I looked at BratStyle in Japan, and gravel Crew, and all of the Visiual Impact builds on this forum, and the few Monster Craftsman builds I could find. I decided I really like the looks of the Monster Craftsman build kit, so thats the route I am headed.

Thanks to Lester and jdizon for the inspiration to proceed down the Swingarm bobber path.

My work space is in the basement of my house with walkout access to the garage, and I have enough room to do whatever I want. I also have a full machine shop in my basement with 3 Lathes, 2 Milling machines, and most of the associated hardware and tooling to go along with it. Just a hobby!
The dirty stuff takes place in my heated garage, where I have a sandblast cabinet, 80 gallon 5 hp compressor, welder etc. I used to have an oven and powdercoating set up down there also, but no longer.

This is not my first Bike build, but will be my first XS650. Other stuff I have done includes this 1982 XV920 Virago that I built for a friend,

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And my 2003 XVS650 that I built (rebuilt) from a bare frame after I crashed it and totaled it.

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Both have many custom one of a kind parts that I machined in my shop. So I hope to do more of the same with my monster brat build.

Jim in Minnesota
 
One of my first posts to XS650.com was looking for opinions on what tank I should use.

I had picked up a Gilera basket case at a garage sale, and one of the things that was included was the tank. The original bike looked like this;

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The basket case I got was the frame, the tins and not much else. No motor, no wheels, no seat, only half the triple tree. in really awful shape. everything covered in brown primer.

Here is my test fit on the XS650 frame before I started cutting off brackets and stuff;

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I like the overall size of the tank, and it has a unique shape that I think will look good on a bobber, so I think I will go for this. It fits really nice with the old tank bracket in front trimmed off.

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I also tried the tank from my old 1971 Yamaha HT1b Enduro. (Another of the Bikes in my basement).

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Jim in Minnesota
 
In early January, I went to a Motorcycle swap meet up in St. Cloud, Minnesota hoping to find anything I could use for my XS650. I really didn't have my build set yet, so I was looking for anything at that point. I was getting ready to leave empty handed, when I spotted what looked like an XS650 mag rear wheel next to a table. Looking closer I noticed that the forks leaning next to the wheel were also XS650. I asked the guy how much, and he pulled a big bin out from under the table which was filled with XS650 parts. $15.00 for everything. I got forks, shaved triple trees, swingarm, the rear wheel, tach, speedo, shocks, wiring, complete headlight assy, front and rear complete brakes, hand controls, basically a full XS650 except for frame, engine, tank, seat, front wheel, fenders and a few small parts.

Most everything was cleaner and in better condition then my original parts.

I was so happy I gave the guy $20.00

This is just a gloat post.

Jim in Minnesota.
 
Subscribed! What a transformation thus far. Man I really dig both tanks, I thought about using a similar tank like the enduro but this is the first pic I've seen it on a brat and really like it. Both look amazing either way. Look forward to your updates :)
 
With my build direction (Swingarm Bobber or Brat depending on what you want to call it) set, I ordered up the Monster Craftsman brat kit

http://www.monstercraftsman.com/yamaha-xs650-weld-on-brat-kit/

And got to work on the frame. Trimming tabs, grinding welds etc. All the ugly came off the frame.

When kit arrived a couple of days later, I went ahad and chopped off the back end and fit the kit. Which generated this thread from me.

http://www.xs650.com/forum/showthread.php?t=25140

But, with a little more fitting it was looking good and I welded it up.

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I like It.

Jim in Minnesota
 
Earlier Today I trekked (50 foot walk through a foot of snow) out to my barn (shed) in the back 40 (backyard) to retreive the box that contained the rest of the parts from the basket case Gilera that my Tank came from. I wanted to see what else was in there that I could possiby use.

I am a happy camper.
I found the following:

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Filler cap and petcocks for my Tank.

And

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Gilera (Aprilia) headlight.

The headlight is pretty rough, the trim ring is trashed, the reflector wont refelct anything, and the blue dot high beam indicator and key switch is missing from the top.

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But check out that Speedometer!!

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I had to do a quick ugly mockup using the XS fork ears.

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It has Possibilities.........

I think I have some 6 inch aluminum round stock in my machine shop. I might have to look at machining a billet headlight rim to adapt a modern sealed beam light into this..

Jim in Minnesota
 
As indicated above, I found the original fuel cap for my Gilera tank. I like it, but I am going to need a bit of a rebuild on it. (new Gasket). Before I found the original I was sort of planning on this..

Here are 2 fuel caps I picked up at the Swap meet In January.

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I was planning on cutting the original fuel cap neck off the Gilera tank, and bolting one of these in. I think they would fit just fine, but I am not sure they fit the style of tank, nor the style of the build I am doing.

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What do you guys think??

Jim in Minnesota
 
There is another Motorcycle Swap meet tomorrow in Minneapolis.

I will be there looking for Fenders, seats, Lights, Oh Hell I will be looking at everything.

Jim in Minnesota
 
Off to a great start. Will be watching your build. Like your choice of the tank and headlight. You are going to have a real eye catcher when finished. :thumbsup: I would go with the original cap for the tank.
 
quickj said:
Earlier Today I trekked (50 foot walk through a foot of snow) out to my barn (shed) in the back 40 (backyard) to retreive the box that contained the rest of the parts from the basket case Gilera that my Tank came from. I wanted to see what else was in there that I could possiby use.

I am a happy camper.
I found the following:

full

Filler cap and petcocks for my Tank.

And

full


Gilera (Aprilia) headlight.

The headlight is pretty rough, the trim ring is trashed, the reflector wont refelct anything, and the blue dot high beam indicator and key switch is missing from the top.

full


But check out that Speedometer!!

full


I had to do a quick ugly mockup using the XS fork ears.

full


It has Possibilities.........

I think I have some 6 inch aluminum round stock in my machine shop. I might have to look at machining a billet headlight rim to adapt a modern sealed beam light into this..

Jim in Minnesota
Click to expand...

Perfect Headlight and Tank combination right there! Hey btw, how often are the motorcycle swap meets in Mn? I plan to visit relatives in Savage next month.
 
jdizon said:
Perfect Headlight and Tank combination right there! Hey btw, how often are the motorcycle swap meets in Mn? I plan to visit relatives in Savage next month.
Click to expand...

J,
It seems like there are at least once a month. There are 2 or 3 comining up in March,

Motorcycle Swap Meet, Saturday March 2nd, 2013 11 am- 3 pm Flying Dutchmen Cycle Club Grounds FREE ADMISSION, LIMITED FREE SWAP SPOTS, for Swap Spots or more Info Contact Butch 507-766-2899. No bikes Inside, Bike Corral Outside, refreshments available. Club Grounds Located Hiway 15 South of New Ulm, take Hiway 68 East approx. two miles turn on 110 Ave. 1/2 mile.

And

SAVE THE DATE: Iowa Classic Scooter & Cycle Swap Meet @ Humboldt
The 22nd Annual Iowa Classic Scooter & Cycle Swap Meet & Show will be at the Humboldt, IA. Fairgrounds on Friday March 15 from 3-8 and Sat. March 16 from 8-3.

This Indoor Swap Meet & Show is open to all types of Vintage Motorscooters & Cycles. Plenty of room so bring your old motor scooters, motorcycles, mini bikes, parts, literature etc. to sell or trade. $5 admission, $10 to Vend. No advance vendor registration required but an e-mail is appreciated so we can estimate table and chair requirements etc.

Please E-mail for the Meet Flyer and more info.
 
Kick ass build Jim!
I have two very similar headlight I plan to use.... one bigger and one smaller than yous... but same style and era. I like the tank too!
Keep the updates comming.
 
My swap meet finds.

So I just got back from the Motorcycle Swap meet. This is what I found.

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A fender.

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Should fit OK with some tweeking. and espically if I do end up running a 19" rear mag on there as is my plan.

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A little round tool box/stash tube thing.

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There should be somewhere that this will fit..

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A set of Panhead Valve covers.

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I thought I could bolt them together, and use them for a battery box/electrical box mounted somewhere on the frame.

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Like this, but with a filler plate between the two pans so the frame tubing is concealed.
I think it has possibilities. Not sure if this is an original idea I came up with, or if I saw it some where. But I like it.
 
Nice score Jim! I like the valve cover idea for electrical box. I like the ridges on the fender, what did it come off of?
 
Great finds! Stash tube is real nice and the Pan cover idea is cool as hell! Hope it works out, haven't seen that one before. Would look nice if you notch them out and have them fit snug on the frame.
Wish there were more Swap meets here. I end up use E-bay but I prefer to tought and feel the crap I buy.... pictures can be misleading.

Lester
 

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