My 78 bobber build thread

ironwill · Posted: April 10, 2009, 4:11 pm Post subject: My 78 bobber build thread

Hi! I am going to post some info on my recent purchase of a '78 XS650, rough, but running, needs work! Comes with a '80 parts bike with a seized motor. I think I'm gonna cut them both up, and make something unique. These are the day I brought them home. The disassembly will begin soon. Thanks for watching!

ironwill · Posted: April 10, 2009, 5:08 pm Post subject: Re: My 78 bobber build thread

Starting to strip her down! Haven't decided for sure whether to hardtail it or not! Question

JLukasik · Full Member Joined: Jun 27, 2008 Posts: 11

no hardtail, build a bike you'll want to ride!

bryant · Full Member Joined: Apr 01, 2009 Posts: 86 Location: KY

hey man. i've been thinkin about what to do with my bike and after looking at stuff online i've changed my mind several times and almost let a few friends talk me out of a couple things. build what you like. Screw what everyone else thinks. If they don't like it they don't have to look at it!

ironwill · Posted: April 15, 2009, 4:00 pm Post subject: Re: My 78 bobber build thread

Hey...thanks for the input! Decided to go with the hardtail, as I dont ride that many miles, mostly to work and back. Picked one up off ebay from TCBros. choppers, very, very helpful. Great service etc. Comes with direction ie. where to cut frame etc. Ive been looking at alot of hardtails on youtube, and really like the look. Actually am anxious to see how it rides, as I've heard different opinions.

ironwill · Posted: April 15, 2009, 4:04 pm Post subject: Re: My 78 bobber build thread

Another pic, still removing parts.

ironwill · Posted: April 16, 2009, 6:12 am Post subject: Re: My 78 bobber build thread

Forks off; more disassembly. Marking all wiring etc.

ironwill · Posted: April 16, 2009, 6:13 pm Post subject: Re: My 78 bobber build thread

Steering head off; taking measurements to start cutting! The kit calls for cutting 3/4" behind the exhaust mounts, but I cut it a little long, and will trim it to fit. I'd rather take some off, than wish I had more! Thanks.

ironwill · Posted: April 16, 2009, 6:15 pm Post subject: Re: My 78 bobber build thread

Here is the hardtail from TC Bros. choppers. Excellant piece. Cant wait to join them! Cool

ironwill · Posted: April 17, 2009, 6:28 am Post subject: Re: My 78 bobber build thread

Finally cut the poor gurl in half! Trying to decipher all the different electronic parts, and which ones are essential to the bike running, and which ones I can live without. Also trying to decide on point or electronic ignition. This unit is currently points, but the parts bike is electronic. Any input on which is better? Thanks!

jayel · Posted: April 17, 2009, 7:47 am Post subject: Re: My 78 bobber build thread

less maintainace on the electronic once you get it working, being 30+ years old the connection in the e-box have probably shook apart, search for TCI repair threads and there are wiring diagrams for minimal wiring setups

ironwill · Posted: April 17, 2009, 3:58 pm Post subject: Re: My 78 bobber build thread

Cool...thanks. I went on biker.net and printed off the wiring info for all the different years. I see mikesxs.com has a Pamco elect. conversion kit. Has anyone tried it? Heres another pic of her from a different angle.

ironwill · Posted: April 17, 2009, 4:00 pm Post subject: Re: My 78 bobber build thread

Wokred on fitting the two together, trimming a little at a time, until it fit just the way I wanted. Lots of measuring from different points to make sure I square, and she shoots straight down the road.

yamaman · Posted: April 17, 2009, 4:07 pm Post subject: Re: My 78 bobber build thread

ironwill wrote:

I see mikesxs.com has a Pamco elect. conversion kit. Has anyone tried it?

Um, you might want to have a look in the Pamco - Electronic Ignitions forum! Wink

yamaman · Posted: April 17, 2009, 4:18 pm Post subject: Re: My 78 bobber build thread

Hey, just a thought! What if someone bought a weld on rear, but they couldn't weld as good as they thought? Or their K Mart welder didn't quite get the penetration they hoped for? Or any of 100 things that a ametuer welder might stuff up?

Don't get me wrong ironwill, I'm sure your up to the task if your going to ride it. No way everyone who does it is any good though!

ironwill · Posted: April 17, 2009, 4:56 pm Post subject: Re: My 78 bobber build thread

Tis a scary thought Yamaman. I havent seen any video on youtube of a Yamabobber going down the road splitting in half, but its conceivable to me that it has happened. I shall check into the Pamco forum, fortunately my welding experience far exceeds my knowledge around the forum. I think of the liability, if you sold a bike you boogered together and the buyer crashed and was hurt, or worse.

ironwill · Posted: April 17, 2009, 6:58 pm Post subject: Re: My 78 bobber build thread

Got everything tacked real good with the engine in place. Removed engine to complete all needed welding. I guess this is the point if, as previously discussed, I weren't confident in my welding skills, I would load her up and take her to a reputable welding shop and do the serious welding there.

ironwill · Posted: April 23, 2009, 3:44 pm Post subject: Re: My 78 bobber build thread

Frame welding!

ironwill · Posted: April 23, 2009, 3:49 pm Post subject: Re: My 78 bobber build thread

Fabbing a brace for the rear disc. Really preferred spoke wheels, but these came on the bike so I will use them for now. Picked the flat fender up off ebay!

ironwill · Posted: April 23, 2009, 3:55 pm Post subject: Re: My 78 bobber build thread

Got the forward controls from TC Bros. Really beefy, nice pieces. May change a few things though!

ironwill · Posted: April 23, 2009, 6:52 pm Post subject: Re: My 78 bobber build thread

Getting tank, and seat mounted! Has anyone resored their engine to look shiny, and new? Mine looks aged, and somewhat oxidized. Not sure if its tedious polishing, or some sort of bead blasting. Anyone have something that worked well for them. Any good ideas would be appreciated. Thanks!

ironwill · Posted: April 24, 2009, 6:23 pm Post subject: Re: My 78 bobber build thread

These next few were actually taken last weekend. My pics/posts have almost caught up with my actual work. Reading a post referring to cookie cutter builds. I guess mine would fit that bill, as it is my first, and I dont really have any strong opinions about what I like etc. I WILL develop them as I go along...I'm sure. My interest in these bikes was sparked by two co-workers talking about the classic XS650/ Triumph thing. I had no clue what they were talking about, so one of them pointed me to a 650 site, and now I'm building one, much to their excitement. I have never seen one of these projects in Maine, so I'm curious what the response will be!

ironwill · Posted: April 24, 2009, 6:27 pm Post subject: Re: My 78 bobber build thread

So thats how they come apart...a grinder! Would like to fashion my own exhaust, can I run it like this, maybe paint the end black. Kinda like a machine gun style, with the cooling holes. hmmmm!

ironwill · Posted: April 24, 2009, 6:28 pm Post subject: Re: My 78 bobber build thread

Cut these "bungs" off the old frame, tacked for now, til I decide on a definite seating position.

What Happened to 650rider.com?

Yamaha xs650