1979 Special Scrambler Build...

Chet Ironhorse

XS650 Enthusiast
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Now that this project is wrapping up I figured I could start a build thread. I have ton's of photos so this may take a while to tell the story..... This all started over 4 years ago when I picked up 2 XS650's. One a complete 1983 Heritage Special, the other a hardtail 1979 Special. I gave the Heritage Special to my Dad as he bought a 1978 brand new and had always talked about them while I was growing up.

The day I picked them up, January 2017
1983 HS and 1979.jpg


The 1979 was basically just an engine thrown in a hardtail frame, no mounts for anything... knowing I did not want a hardtail I traded that frame for a stock 1979 Special Frame.

XS.jpg


After I first swapped the parts over to the stock frame.
XS stock.jpg


Then I started making it my own...

Made a headlight mount....
light (2).jpg


lighting (4).jpg


I wanted to stick with the large 7'' light, but this pushed things out too far... so I made a different one...

Hugh light bracket (1).jpg


Made a few brackets for the rear lights and mounting for the inner fender...

lighting (1).jpg


lower fender mount.jpg
 
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The first thing I had powdercoated was the wheels..
Wheels.JPG


Then I drilled the rotors. I had a buddy draw a pattern up in illustrator then print it out on clear vinyl. Stuck it to the rotor so I could center punch all the holes.

Rotors.jpg


Shaved the upper triple clamp and fork leg...
3212017 (3).jpg


Milton mod for the forks..
Forks (2).JPG
 
Bobbed the front fender which I didn't up using... still trying to figure out a good looking solution for this...

Fender (1).jpg


Fender (2).jpg


Fender (3).jpg


Exhaust was next, this took FOREVER!
Tubing.jpg


Exhaust (2).jpg


Exhaust.jpg


Roller (1).jpg


Roller (2).jpg


At this point in time I had gotten the front end back from powder coat as well as the brake calipers and mounting brackets... starting to look like a bike..
brake brackets.jpg


Calipers.jpg
 
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What fork legs are you using to run the small rotor?
 
Man thats gonna be one sweet scrambler. Are you doing all the powder coating yourself?
 
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