steveair2's '78 XS Chopped Hard Build

[Steveair2]

Checking fit of brake linkage and shortened some studs so I could use acorn nuts on my foot peg mounts. Some how I lost the brake bell crank bushing, I’ll have to make another one.

 

[Steveair2]

I found the spacer!

 

[Steveair2]

Got lucky and found a 1/8” sheet of 4130.
Cut and bent a new right side engine mount.
Came out beautiful then drilled the bolt holes oversize and screwed it up. Also ran out of acetylene bending the left side. This 1/8” 4130 ain’t no joke! Takes a lot of heat and hammer.

 

[Steveair2]

Since I ran out of welding gas I decided to make some new axle adjusters. I’m using 5/16” metal punched out of semi truck fifth wheel slider plates. I used to work at the factory.

 

[Steveair2]

So the radius I cut off the 5/16” plate ended up being an exact fit for the brake stay. Just one cut and a little shaping. It took me forever to smooth off the top of the brake cylinder cover.

 

[Steveair2]

Some how I managed to get the tail light mount fit and tacked on. I’m no good yet at using my new MIG welder. I’ll fix it when I get some gas.

 

[Steveair2]

Some how I bent the front engine mounts at the right angle

 

[Steveair2]

I made some progress on the right upper engine mount. The terminal block was scavenged from a Dallas jail telephone system. It was new in 1963.

 

[Steveair2]

Today I used my new Tig welder to tack in the TC Bros chain tensioner. I wish I could have gotten a Tig welder years ago, I never could afford one. They make welding much easier.

 

[Steveair2]

Today I redesigned and fabricated the switch housing mount.

 

[Wingedwheel]

I like the location of those switches.

 

[Steveair2]

Thanks Wingedwheel.

Today I finished making the smoke oil pump bracket.

 

[Steveair2]

I’ve done some welding, grinding and cleaning over the past few weeks. Today I fit the oil system bungs.

 

[Steveair2]

I spent the last few work sessions cutting and shaping the kickstand mount. Today I was able to weld it into position. I had to sit the bike on the floor for the first time in ten years to get the angle right.

 

[gggGary]

smoke oil pump.

Wait...... What???

Great job on the side stand, the way it's nestled in under the peg mount when retracted.

 

[Steveair2]

Thanks for the nice comment Gary.
I spent Memorial Day completing all the welding on the frame. I’ve been spending a few hours a day priming and wet sanding.

 

[Steveair2]

Today I did some filling, priming and sanding.
Then I decided to glue my tail light wires to the frame.

 

[Steveair2]

Today I did some filling, priming and sanding.
Then I decided to glue my headlight wires to the frame.

 

[Steveair2]

Wow! Only eighty seven degrees in Dallas tonight. Definitely getting some wet sanding done.

 

[Steveair2]

Today I did some filling, priming and sanding.
Then I decided to make a tail light wire/fuse housing out of a fence post cap I robbed off my back yard fence post.