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Old 09-26-2008, 09:41 PM   #1 (permalink)
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Punkskalar Builds A Bike / Chopperthing....

Well, I've never had a build thread, and I've built several trail rigs in the past. Built a few buggies where I was working as well, and hotrods, etc...

Ive never built a bike. My dad used to build bikes back in the late 70's early 80's. Even my Grandpa used to soup up his Cushman motorscooters.

So I decided to build a bike, but it had to be on a budget. I've gone back to school (I'm 28) so money is tight, but I still turn wrenches on most all of my old customers cars on the side. Mostly imports (used to work as a tech at the local Honda dealer).

So I picked up a 1981 Yamaha XS650. Not the baddest of all bikes out there, but they have a strong, almost cultish, following. I'll dig up a pic of it while it was complete. Here it is gutted.

Hugh Owings Motorcycle Bobber Chopper XS650 XS 650 Honda Rebel CMX250

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Old 09-26-2008, 09:44 PM   #2 (permalink)
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So I took a job on campus as the Lab Tech in the metals shop. Its minumum wage, but I get 24/7 access to all the tooling and materials I want. No cost to me for metal, bits, drills, etc... Not a bad gig when you wanna build a bike. Decided to turn down the front forks. I plan on running fenderless on the front, and the factory forks have brake mounts on both sides. This was my first time in about 8 years working on a lathe. Keep in mind, I have never polished anything in my life from raw metal.

Hacked off the mounts with a hacksaw / anglegrinder

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Old 09-26-2008, 09:46 PM   #3 (permalink)
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The factory forks have high and low spots all throughout. I originally wanted to just take off enough to make them smooth, but decided to remove the factory taper and make them 100% Straight.

This took me a while, 5 hours exactly.

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Old 09-26-2008, 09:49 PM   #4 (permalink)
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The other side I had to keep the brake mounts, and that proved to be a tougher job than I thought. I turned the other fork down to 1.8" all the way down. I had to turn the upper part, then the part between the tabs. Here you can see I had quite a bit of work ahead of me to blend all this in by hand.

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Old 09-26-2008, 09:54 PM   #5 (permalink)
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The above picture was still way oversize, but I didn't get a good picture of the amount I had left around the brake tabs. I bought a 90 degree die grinder and a handful of Roloc disks. After lots of grinding, sanding and polishing, I ended up with this.



Those coves near the seals and caps were a major pain to machine, but they ended pretty nice. Both legs ended up at 1.8" around.

Ended up with a few waves near the brake mounts, but 10 hours later I had a pair of polished fork tubes. Not 100% perfect, but I had to remove some deep scratches in a few places, but I'd rather have a little wave that most won't notice than deep gouges in the aluminum.
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Old 09-26-2008, 09:59 PM   #6 (permalink)
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Next up is the front hub, I wanna remove the factory casting ribs and polish it up. Im only going to 400 grit (free sandpaper) and then polishing using turtlewax polishing compound. Figure if it gets too dirty in the future, I can just scotchbrite it

Cutting out the hub (planning on using a 21" front rim laced to this one)



The "ribs" i want to remove. Hopefully there is enough meat in there

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Old 09-26-2008, 11:49 PM   #7 (permalink)
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Cool build I just started a bobber/chopper thingy build on a 1982 yamaha XJ650 I just got.
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Old 09-27-2008, 12:04 AM   #8 (permalink)
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i built a chopperthing before.... it was a fun time consuming project that kept me busy!

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Old 09-27-2008, 12:10 AM   #9 (permalink)
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That ^^^is way too fawking kewl!^^^
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Old 09-27-2008, 12:46 AM   #10 (permalink)
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That ^^^is way too fawking kewl!^^^
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Old 09-27-2008, 12:46 AM   #11 (permalink)
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nice work on those forks, they look awesome.


BTW, that bicycle/chopperthing is
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Old 09-27-2008, 05:25 AM   #12 (permalink)
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i built a chopperthing before.... it was a fun time consuming project that kept me busy!

So I was reading my state driving manual. Who woulda guessed that it is illegal to modify the handlebars on a bicycle so they are higher than your shoulders?

I like both bike projects.
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Old 09-27-2008, 07:28 PM   #13 (permalink)
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Got the front hub turned down and polished today. Getting those huge casting marks out was a bitch. I had to chuck it up in the mill, remove the casting marks, then put it in the lathe and turn 1/2 of it down, then flip it in the lathe and turn the other 1/2. Lots of sanding to blend the 2 halfs together since the lathe has 1/2 dead bearings.

6.5 Hours later...

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Old 09-27-2008, 09:14 PM   #14 (permalink)
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that is HAWT! good job! clear coat and done.
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Old 09-27-2008, 09:29 PM   #15 (permalink)
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dude those old lathes are so beat, i ruined like half of the stuff that i tried to make on those things. how is old dave dommermuth doing there? i havent seen him in quite a long time. at least the mill works good so you are not totally F-ed
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Old 09-27-2008, 09:37 PM   #16 (permalink)
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Where the hell is PeeWee Herman?!

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Old 09-27-2008, 09:59 PM   #17 (permalink)
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woahhh hoohhhh!! HAHH HAHH!!!
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Old 09-28-2008, 09:41 AM   #18 (permalink)
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Quote:
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dude those old lathes are so beat, i ruined like half of the stuff that i tried to make on those things. how is old dave dommermuth doing there? i havent seen him in quite a long time. at least the mill works good so you are not totally F-ed
Yeah, I had my work cut out for me. Double D is still kickin around, you know how he is.
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Old 09-28-2008, 10:10 AM   #19 (permalink)
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I have one of those engine kits sitting in the living room right now. Would love to build something along these lines. Boardtracker stye

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Old 09-28-2008, 10:38 AM   #20 (permalink)
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That is sick, what kind of motors are they?


Btw nice build, its cool to see something different
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Old 09-28-2008, 12:00 PM   #21 (permalink)
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Most of them appear to be the 50-80cc engine kits you can get off of ebay. Cheap chinese stuff, but people seem to be having alot of luck on them.

BTW, the above picture is not what I am building currently, but would be a fun project nontheless.
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Old 09-28-2008, 12:30 PM   #22 (permalink)
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Quote:
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BTW, the above picture is not what I am building currently, but would be a fun project nontheless.
Yeah I was talking about your project...
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Old 09-28-2008, 01:09 PM   #23 (permalink)
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Gas Tank I picked up. Its from a 1957 "James" L15 Cadet 150. I can't find much information on it, but I thought it was a sweet tank, complete with a rib that runs the full length of the tank. No cap as of yet, and it looks like a straight tube for a filler, no grooves or places for a cap to fit onto. Who knows?



The badges on the side are actually plastic, and one is cracked but not badly, can't decide whether to keep them or make new ones with my name on them

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Old 09-28-2008, 01:15 PM   #24 (permalink)
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Got a 21" 36 Hole Akront drop center aluminum rim. These things are like gold apparenty, but I got it super cheap (poorly listed on ebay). Usually found on dirtbikes, so they got the piss beat out of them. This one came from an 68' OSSA i think. I need to do some polishing and weld up an extra hole ??? that it had for an innertube? We have a tig at school, but its bigger than my refridgerator and im not sure anyone in the building knows how to use it.



Rear rim is from a 73' Husqvarna WR 450, 18" and same style / brand. Had to get the whole wheel and cut out the hub.

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Old 09-28-2008, 01:23 PM   #25 (permalink)
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So obviously I have been in the parts gathering stage. With Studio (Industrial Design Major) I am super busy until December, but I wanted to start getting things ready to go for assembly.

I originally wanted to make the front brake operated with my right foot. But between that, jockey shift and a foot clutch, I figured I better play it safe and use a handbrake for the front (for now)

Got in a brake lever from a Kawasaki ZL 600. I really wanted a round fluid reservoir (hoping to emulate a 50's - 60's style)





Ended up alot bigger than I wanted, may have to cut down the reservoir and lever a bit. (open to any suggestions on other levers/reservoirs as well)
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