Jim's Hard Tail Project

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Hi everyone. Been thinking about building an xs for a few years now, and finally just decided to go for it. The bike is a 72 that i found on craigslist. Its going to have a tc bros hardtail, hopefully 21" wheels (front and rear) both with drum brakes, and a cool old benelli gas tank. Thats the basic plan for now.

Jim

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

More pics

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

I'll post more pics in a week or so. Going to a concert in chicago this weekend, so wont get much done..... by then back end should be cut off.

jim

bbjsw10 · Full Member Joined: Jul 15, 2009 Posts: 64

Nice start, be ready for the whiners though. It is a 72, that is why they will whine.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Yeh, i have a 75 thats been in the family since it was new, so i definately wasn't going to cut that one up. I figure the only ones that are worth not modifying are xs1's and super low mileage bikes. just my opinion.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

I had some time to work on my bike tonight. I leveled the bike on the stand and tack welded everything in place. Then on with the cutting. I'm really glad that i braced the frame so much, because after every cut was made, that bar would spring an eighth of an inch out alignment on the scrap side...... Anyways, just have the back end hacked off. I have to make the final cuts on the lower rails, and grind away all of the stumps of the old subframe. One thing I was wondering about is that the "slug" that tc bros suplied for the downtube crossmember, doesn't fit tightl in my downtube. It is only 1" in diameter, whereas my downtube is 1 3/8" inside diameter, leaving 3/8" of play. This doesn't seem right to me, I have to re read my instructions. I think I'm just going to find a piece of tubing that fits inside and notch it my self for a tighter fit, cause that other thing, will not work as is. I'll take pictures of this dilemma later.

jim

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Got some work done today. Cleaned up all the cuts made to the frame and then fitted the hardtail section. It fits pretty good, but not as good as i thought. I had to fit a piece of tubing inside the downtube, and then stick the supplied slug into that to get a nice snug fit. I'm not shure if the bottom rails are suppose to be at that much of an angle, but i kinda like it. Also, the directions say that the upper rails are supposed to end up on the stamped part of the down tube. They are a little bit to far forward, but should work. I think this hard tail is more designed for the newer models of xs 650. but here is what i have so far.
jim

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

I guess the frame isn't at ride height though, so the angle shouldn't look so weird once i get wheels on it. Its not welded up yet, so i can still tweak things a little. Input is welcome!

jim

Teebs · Full Member Joined: Aug 26, 2008 Posts: 255

Looking good, jim. Man is that thing going to be LOW! Prepare to relocate your kickstand.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Not Much of an update, but more/ better quality pictures! I drilled all the plug weld holes and did a final fit on the hardtail. It is now squared up and tacked into place, ready for final welding. The last picture is of the sleeve in the backbone mentioned earlier. Feels really solid now and there is no slop in the fit. I need to start looking for or building a seat soon. I like the look of biltwell seats, but not shure if i want to shell out that much cash.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Oh, and I found these on top of my fork springs when i took them apart. Not exactly shure if they are supposed to be there. Ive seen some guys do it your self thread, and I think he said that the spacers for under the spring, not shure? I want to lower these forks, but i have to look into it more..... any coments or suggestions always welcome

jim

jayel · Posted: August 18, 2009, 9:15 pm Post subject: Re: Jim's Hard Tail Project

those are longer than the stock spacer, damn PO stiffening up the fork trick, yes they go to the top of the fork not under the spring ... part #19

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Cool, thanks for the sweet exploded view! Yeh I thought that they looked a little off, being as they had burs on each end and look like plumbing materials....

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Good news. Frame is welded solid and ive got a rear wheel on. Its not the wheel I will be using, but its one I have laying arround. Also removed tank cups. I still need to trim the front ears on the benelli tank to make it fit right. Front fend is going to be used as the rear, i just have it sort of sitting in place, it wont be fit properly until i figure out wheel and tire combos. thats it for this weekend! Also note that my forks are practically bottomed out so it should sit higher in the front. Although it looks bad ass that way.

jim

mmasac · Posted: August 23, 2009, 7:14 pm Post subject: Re: Jim's Hard Tail Project

Looks great, the benelli tank looks pretty slick on there. I cannot wait to find me a xs650 and get to chopping.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Thanks! Here are a few more pictures.

jim

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Put some time in today! I trimmed the tank ears so it would fit closer to the neck. I still need to take a bit more off, but im trying to be careful not to damage the original paint. I will have to brainstorm a bit to come up with a rear mount that will look good... The bars are some clubmans from ebay. Not shure if I want to leave them upsidedown like they are or put them the normal way and just run really low bars. I guess it all depends how everything feels as far as foot positioning and such. The seat is partially mounted. It is a biltwell unit with their stainless steel mounting bracket, which is tig welded in place. I dont have any springs for it yet, as I wasn't shure how tall I needed. I'm going with the torsion style or "hairpins" that are 3". Also, I switched out the rear wheel to an 18" which is what I think I will be running. I know that I wanted to do a 21" rear earlier, but I really want to run the piss out of this thing and I dont want to think about a front tire on the rear coming apart on the highway. So I'll just play it safe. Comments and suggestions welcome!

jim

blackwidow · Posted: August 30, 2009, 12:17 pm Post subject: Re: Jim's Hard Tail Project

nice work

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Put the engine back in tonight. Seat springs arived the other day as well. Also moved seat crossmember to line up with the seat springs.

To anybody using a tcbros hardtail or anyone familiar with: Do you think my seat position looks weird compared to other builds using tc bros hard tail? I mounted it pretty high compared to others; thats what I'm seeing at least.

jim

Teebs · Full Member Joined: Aug 26, 2008 Posts: 255

Hey jim, the bike's looking good. I did notice the seat was sitting higher and doesn't look quite right. Also, if you're going to run forward controls, that position might be a little uncomfortable. With mids it might not be too bad.

Keep it coming, can't wait to see it finished.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

Yeh, Ive been planning on using mid set controls. I wanted an agressive riding position, not a slouched/stretched out kinda deal. I guess thats why I put the seat up higher and I'm using clubman bars...I sat on it, it felt pretty nice, but I wont know for shure until I make my foot controls. I think it looks good, following the line from the bottom of the tank. I guess we will have to see. Again, thanks teebs.

jim

nickmo · Full Member Joined: Jul 21, 2009 Posts: 49

CLUBMANS DOWN!!

So say I.

I like the seat up a little higher BTW.

jimxsrider · Full Member Joined: Oct 31, 2006 Posts: 67

new pics today! Sorry for no updates lately, but ive been working on the little stuff..... foot peg mount, foot pegs, seat spring mounts, etc.....
But here it is as it sits lately, virtually unchanged, just off the table and on the ground. I wish i could leave my forks bottomed out like this, it looks so cool. was thinking that a shortened springer would look cool and allow me to keep it that low. Its got about 3-3/4" of ground clearance. With the 21" wheel on the front it should bump that number up an inch, so when the forks are in the right position i will probably have way to much space between the frame and the ground....trying to figure out how to keep it this low should be fun.
comments and suggestions welcome

jim

danxs650mass · Posted: October 22, 2009, 9:34 am Post subject: Re: Jim's Hard Tail Project

hey nice work i like the tank i found a bennile tank to use to i was wondering what you were gona use for a petcock i still havent found one for the tank im plan ning on useing?? thanks you ever think of going to a 16 inch rear wheel ?

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