BobbedSled
XS650 Addict
My XS650 Scratch Bobber build
HI all, I'm new here. Figured I share XS my build. I always wanted to build a bike, don't really have a craving to ride one, it is is a bucket list thing as much as anything. "Build a motorcycle from scratch". Kids can ride it when I am gone. Figured I'd post it up so maybe someone else can get something from it. I will definitely need help when it comes motor break down and rebuild time. Maybe something here will help someone in the mean time.
I raced MX for years but street seems unsafe but I am still drawn to them. I love bikes in general but I am kinda anti Harley with all the branding and clothing that seems mandatory when you ride. Almost cult like. I mean that's fine if that's your thing, I just don't follow the pack that way. In fact I head the opposite way. SO I decided to build a metric type bike.
What I like is vintage cafe raceways and bobbers that are not all chromed and shiny with mega dollar paint jobs. More home garage type of thing less store bought type of thing. Something different of you follow what I mean.
After watching all those biker shows it did not seem that hard. Decided if I was going to build it that I would build it and not chop an existing frame. I suppose I will have problems with registration but I'll cross that bridge when I get there. Kept all receipts including those for the raw metal.
Started looking around, Meritc is the way for me, v-twins were OUT. Wound up opting to use XS650 engine based on all the aftermarket stuff. I wanted to build something a bit different but familiar. Kind of dragged/cafe/bobber type of sled. Sort of long but not 2005 absurd, sort of low but not too low, kind of old school but yet still contemporary looking.
Anyhow it makes sense in my head.
So designed a frame in CAD that is based on sort of like an old school chopper type of rigid. I then made a frame jig for 1 time use, bought a tube bender, bought a notcher and Miller 211 and some new tools and compressor yada yada. Franky the tools will cost as much as the bike but we all loves our tools.
I have never worked with metal before this is my first time building anything so bear with me. I am sure veterans will find all sort of mistakes, but that is the point for me to learn.
So here we go, I am dying to see how it turns out myself. If nothing else I'll learn a lot. While it is not super easy it is way easier than I though it would be.
Here is the jig, does not look like much but it is square and is intended for 1 time use.
First thing is bend some tubed for the rear wheel hoops. This type of design requires 1 bend per tube which makes it easy. I used 1.25" OD HREW tubing which was .120 wall. It requires one 90 degree bend. It takes like a 96 degree bend as the tube bounces back. Lots of trial and error there. I had to re-buy lots of tube, but it is pretty cheap.
I used Pro-Bender and their dies, made a rolling base for it and added harbor freight air over hydraulic ram. Works really really well.
Here we go all 4 done, put a 1" tubing slug in the end
Lay it in a jig and clamp the ever loving crap out of it for welding.
Reverse it in the jig so it sticks out so I can finish welding the other side that was facing down in the jig for initial alignment.
Start sanding with angle grinder and flap wheel.,
When done it looks like 1 piece of tube.
Now add some end caps, Clamp and weld Mig them, looks matter not here it gets all ground off.
Then sand them down, this is before final sanding but you can see it gets smoothed out pretty good.
By the way check out that band saw in the pic above. It is just a Milwaukee hand held deep cut band-saw. Swag offroad sells a table that the hand held unit mounts to. Super simple and super small form factor and super effective for what I need.
Got axle plates cur by local water jet shop
Mark for cuts and then cut
Walla done, now just duplicate the other half.
HI all, I'm new here. Figured I share XS my build. I always wanted to build a bike, don't really have a craving to ride one, it is is a bucket list thing as much as anything. "Build a motorcycle from scratch". Kids can ride it when I am gone. Figured I'd post it up so maybe someone else can get something from it. I will definitely need help when it comes motor break down and rebuild time. Maybe something here will help someone in the mean time.
I raced MX for years but street seems unsafe but I am still drawn to them. I love bikes in general but I am kinda anti Harley with all the branding and clothing that seems mandatory when you ride. Almost cult like. I mean that's fine if that's your thing, I just don't follow the pack that way. In fact I head the opposite way. SO I decided to build a metric type bike.
What I like is vintage cafe raceways and bobbers that are not all chromed and shiny with mega dollar paint jobs. More home garage type of thing less store bought type of thing. Something different of you follow what I mean.
After watching all those biker shows it did not seem that hard. Decided if I was going to build it that I would build it and not chop an existing frame. I suppose I will have problems with registration but I'll cross that bridge when I get there. Kept all receipts including those for the raw metal.
Started looking around, Meritc is the way for me, v-twins were OUT. Wound up opting to use XS650 engine based on all the aftermarket stuff. I wanted to build something a bit different but familiar. Kind of dragged/cafe/bobber type of sled. Sort of long but not 2005 absurd, sort of low but not too low, kind of old school but yet still contemporary looking.
Anyhow it makes sense in my head.
So designed a frame in CAD that is based on sort of like an old school chopper type of rigid. I then made a frame jig for 1 time use, bought a tube bender, bought a notcher and Miller 211 and some new tools and compressor yada yada. Franky the tools will cost as much as the bike but we all loves our tools.
I have never worked with metal before this is my first time building anything so bear with me. I am sure veterans will find all sort of mistakes, but that is the point for me to learn.
So here we go, I am dying to see how it turns out myself. If nothing else I'll learn a lot. While it is not super easy it is way easier than I though it would be.
Here is the jig, does not look like much but it is square and is intended for 1 time use.
First thing is bend some tubed for the rear wheel hoops. This type of design requires 1 bend per tube which makes it easy. I used 1.25" OD HREW tubing which was .120 wall. It requires one 90 degree bend. It takes like a 96 degree bend as the tube bounces back. Lots of trial and error there. I had to re-buy lots of tube, but it is pretty cheap.
I used Pro-Bender and their dies, made a rolling base for it and added harbor freight air over hydraulic ram. Works really really well.
Here we go all 4 done, put a 1" tubing slug in the end
Lay it in a jig and clamp the ever loving crap out of it for welding.
Reverse it in the jig so it sticks out so I can finish welding the other side that was facing down in the jig for initial alignment.
Start sanding with angle grinder and flap wheel.,
When done it looks like 1 piece of tube.
Now add some end caps, Clamp and weld Mig them, looks matter not here it gets all ground off.
Then sand them down, this is before final sanding but you can see it gets smoothed out pretty good.
By the way check out that band saw in the pic above. It is just a Milwaukee hand held deep cut band-saw. Swag offroad sells a table that the hand held unit mounts to. Super simple and super small form factor and super effective for what I need.
Got axle plates cur by local water jet shop
Mark for cuts and then cut
Walla done, now just duplicate the other half.
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