Thumper Club Forum
Technical => Project Progress => Topic started by: guest526 on November 30, 2008, 09:45:23 PM
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Hi there,my name is Adrian,I've mean lurking around here for the last 6 months or so.Picked up lots of good advise going through the archives ,so no stupid questions just yet.Anyways I won a XBR on evilbay some 3 years ago,in fact 2 as it came with a spares bike.The bikes been great,ideal for tearing down the streets around NW London where I live.Still runs like a champ but it's as tatty as a bachelors MZ.So it's makeover time and always wanted to build a cafe racer.
Ok,so far Ive stripped the bike down to the frame,proceeded to grind any tabs not needed and shortened the back end.Next I had extra tabs welded on the rear rails for the Ducati (!) tail piece I intend to fit,I also had an extra tube welded between the 2 back stays for the oil tank to bolt to.
Now its just come back from the powder coaters,some pics .(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0019.jpg)(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0025.jpg)(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0021.jpg)(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0022.jpg)
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Good work that man - keep us posted
GC
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I too have an XBR in bits- I was hoping to get rid of the airbox, would I need to support the top as you have in your pics, or is there another way? (frame already powder coated...)
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I too have an XBR in bits- I was hoping to get rid of the airbox, would I need to support the top as you have in your pics, or is there another way? (frame already powder coated...)
Hi Dave,yep iam junking the airbox and side panels and i plan on putting the battery under the rear tail piece.You can support your oil tank with brackets,check out "XBR 666"on this sitehttp://rfvc-racing.npage.de/index.html (http://rfvc-racing.npage.de/index.html)
hope this helps
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Coooool!
(http://file1.npage.de/000231/91/bilder/666_2.jpg)
And it looks alarmingly like it's still road legal :)
Nice peg hangers... someone has access to some CNC kit I'd say.
GC
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That is wicked- a bit beond me, perhaps, but I like! ;D
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By the way- Hurley, your bike looks cool to, looking forward to when its completed ;D
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What a beauty !! I`ve enough bits to build one............. Ahhhhhh :D
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Where did they find that seat unit??? :o
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It's either a Honda GB500 seat or a G50 Matchless race seat... I'd say GB500
GC
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Aha! And what have they done with the battery? Or dont they need it?
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Also= whats he hung the bracket off? Ive had a look and I have some captive nuts where his bracket is, so maybe I could use the same idea- what normally fixes there???
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There is a u-shaped oil tank bracket that bolts to the brackets on the frame. It also acts (iirc) as the battery holder and has lugs for some of the electrical components.
GC
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Adrian, is your user name a homage to that great marque the 'inextinguishable' Hurley Pugh, manufacturer of machines famous for, amongst many other things, supplying escort bikes to 10 European royal families in the inter-war years?
See more HERE (http://www.hurley-pugh.co.uk/hpechome.html)
If there's one thing that modern bikes lack, it's an umbrella rack ;)
GC
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Coooool!
(http://file1.npage.de/000231/91/bilder/666_2.jpg)
And it looks alarmingly like it's still road legal :)
Nice peg hangers... someone has access to some CNC kit I'd say.
GC
In matt black it might at first glance look a bit of a rat bike,but this machine has got titanium bolts and spindles ,carbon fiber seat base,loads of CNC machinig,everthiig has been drilled or milled to save weight.All the electrics are stuffed under the GB500 seat,some tiny battery because the electric start been removed.Its worth book marking this site,its updated often,its amazing what engineering types with way too much time on their hands can do to the humble XBR.
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Adrian, is your user name a homage to that great marque the 'inextinguishable' Hurley Pugh, manufacturer of machines famous for, amongst many other things, supplying escort bikes to 10 European royal families in the inter-war years?
See more HERE (http://www.hurley-pugh.co.uk/hpechome.html)
If there's one thing that modern bikes lack, it's an umbrella rack ;)
GC
Spot on,previous owner of my bike was Tony Sleep ,the man behind the legend that is hurley-pugh,in fact,until recently the bike was emblazoned with all sorts of hurly-pugh graphics.Tonys areal funny guy ,the sites a piss take of old farts who are still, convinced old brit bikes are best.Tony used to be photographer on "Bike" magazine and my Xbr was the long term test bike .
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NOT the XBR they slapped the sidecar on! I'm sure I've got the article here somewhere.
I was on a bike trip in China in '88 and one of the other guys worked for Superbike magazine. We got to talking about XBRs and his description of teh performance of their test bike bore no relation to my new(ish) example... it sounded much pokier and crisper. I always wondered if Honda had carefully 'assembled' their test bikes.
GC
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So could I run the bike without a battery altogether? Or do I still need one somewhere.
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NOT the XBR they slapped the sidecar on! I'm sure I've got the article here somewhere.
I was on a bike trip in China in '88 and one of the other guys worked for Superbike magazine. We got to talking about XBRs and his description of teh performance of their test bike bore no relation to my new(ish) example... it sounded much pokier and crisper. I always wondered if Honda had carefully 'assembled' their test bikes.
GC
Ah yes the XBR with the chair,that ended up crashing down a ditch whilst loaded with trappist bear (sidecar and presumably the rider).Don't know how true this is but I do have the remains in my shed as a spares bike ,no sidecar though.Would be cool if my #1 XBR was a factory special ;D
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Got some work done today-forks fitted.Easy job as i had rebuilt them earlier this year (new seals+hagon springs),only problem was state of the paint on the fork legs,a very tedious afternoon spend spent sanding the paint off and polishing the alloy,much tidier now.(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0005.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0003.jpg)
teleflex fork brace
(http://i491.photobucket.com/albums/rr277/cloda12/RIMG0004.jpg)
original clip ons inverted and switched left to right and fitted below the fork bridge,also note the fork stanchions pushed through fork bridge an extra 10mm,to quicken the steering a bit.
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Looking good- I stripped my fork legs too, god knows what Honda put on them- are you fitting stainless bolts? I'm trying to get some, but struggling to get all I need from one place...
;)
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Looking good- I stripped my fork legs too, god knows what Honda put on them- are you fitting stainless bolts? I'm trying to get some, but struggling to get all I need from one place...
;)
I'am using the original honda bolts on safety critical stuff like forks and brakes,everything else stainless if I can.I got a kit of ss bolts for the engine off German Ebay,Screwfix to a range of ss bolts cheap that could be useful
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Either that, or try these:
http://www.stagonset.co.uk/fasteners?output_frontpage=yes&clickthrough=adwords&keyword=stagonset&gclid=CIjvxayc_ZICFRW5GgodhgUfHA
http://www.inoxgrp.co.uk/pdf%20files/Brochure/brochfull07_04_10.pdf
http://www.custom-fasteners.co.uk/downloads/2008catalogue.pdf
These are what I'm using, they seem to have most bits between them...
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More bits bolted on today
(http://i491.photobucket.com/albums/rr277/cloda12/002.jpg)
Koni dial a ride
(http://i491.photobucket.com/albums/rr277/cloda12/009.jpg)
cut down LH foot peg plate, modified BMX tricknuts for pegs.
(http://i491.photobucket.com/albums/rr277/cloda12/005.jpg)
More next time :)
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I say, rather fetching old chap.
Good work
Toodlepip
GC
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Looking lervly ;D think I'm geting jealous >:(
;D ;D ;D
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Its looking really good- can you show us pic of your seat your having on it? Mine hasnt moved on much, I need some bolts but Im hoping when I get them it'll kickstart me into getting on with things.
Keep up the good work! ;D
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Its looking really good- can you show us pic of your seat your having on it? Mine hasnt moved on much, I need some bolts but Im hoping when I get them it'll kickstart me into getting on with things.
Keep up the good work! ;D
working on the seat unit right now Dave,should have some pics to post on Sunday
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So,after much messing around in Photoshop,I finally chose this tail piece
(http://i491.photobucket.com/albums/rr277/cloda12/001-1.jpg)
It's off a 1990 Ducati 900 superlight,very luckily one was on Ebay at the time.
(http://i491.photobucket.com/albums/rr277/cloda12/002-1.jpg)
XBR light fitted easily enough.Now the hard bit,fabricating a seat base and battery holder,many hours later this is what I have come up with.
(http://i491.photobucket.com/albums/rr277/cloda12/001.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/008.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/003.jpg)
and now with the tail piece fitted(http://i491.photobucket.com/albums/rr277/cloda12/003-1.jpg)
Still got a bit more detail work to do here,but you get the general impression-oh and I don't like the red,probably paint black/white latter.
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NICE!
I've always liked that seat unit, the Superlight is one of Ducati's prettiest bikes.
GC
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Finally found some time to tidy up and paint the engine.First of all I removed the crankcase covers and polished them up,didn't have the time or patients to get them mirror-like but they're way better than the paint blistered mess that they were.Next I attacked the rest of the engine with a angle grinder with a wire wheel attachment,this made a great job of cleaning up the engine and an equally good job of messing up the patio.I left the crankcase unpainted,but I painted the barrel in black VHT paint,and the head silver.Whilst the covers were off, I removed the oil filter screen,wise move because it was half blocked with crud.Finally I refitted the covers and fitted new a/key stainless bolts .
(http://i491.photobucket.com/albums/rr277/cloda12/det.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/der.jpg)
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Aye Hurley,
Nice clean motor that looks all the better for NOT being mirror, power to your elbow :)
More Solvol, Bill.
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That's sexy!
And Themoudie is right, it's better for not being mirror-polished
GC
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And... what type (or grade) of wire wheel attachment did you use on the grinder? I'd have thought that it would have scored the aluminium, but apparently not.
GC
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And... what type (or grade) of wire wheel attachment did you use on the grinder? I'd have thought that it would have scored the aluminium, but apparently not.
GC
Yeah I should have pointed out ,before anyone defaces their engines,that I used a fine spring steel wire wheel and didn't press too hard either,worked a treat.Also, I agree with you about overdoing the polishing,apart from the fact I hate doing it,I think old bikes look better with a bit of"patina",adds a bit character,shows the bikes has a bit of history and whats more ,gets used
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Good work. Fancy doing the same to my bike...? ;)
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Ok so I rather foolhardily thought fitting the engine back into the frame would be an easy one man job and so gave it no real thought,this was possibly because;
A, I 'd all ready forgotten what a PITA it was to get out
B, The manual just said "refit from the left hand side" ;D.
C, I 'd just been watching orange county choppers (or what ever it's called) on the box,where some fat bloke lifted up a HD engine and just dropped into the frame of their latest comical creation,10 seconds, job done.
My first attempt only succeeded in me bending one of the engine mounts,lacerating my fingers and the bike falling over.
Time for a Zen (and the art of motorcycle maintenance ) moment,i.e,a lie down in a darken room for a while.
Suitably refreshed in mind and soul, I attacked the job again, this time with renewed vigor.I had a good look, and planned my manoeuvres .Lifting the engine I twisted it into the frame at a tighter angle and after much tooing and throwing ,there was a sudden jerk and in dropped the engine. :D
the fruits of my labours
(http://i491.photobucket.com/albums/rr277/cloda12/engine.jpg)
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Looking good, coming along nicely (and quickly)
How did you get on with the engine bolts off ebay?
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Looking good, coming along nicely (and quickly)
How did you get on with the engine bolts off ebay?
Thanks Dave,I really only have a few hours a week to do my bike,but it's getting there-ebay bolts all good.
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Well you're doing better than me:
I started dismantling my XBR at in October 2007.
Its still in bits. :o
I have the enthusiasm, but not as much time as I'd like.
Plus I seem to do things over and over again... :-[
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I started making my XBR cafe racer in 1988 :o
The engine is a bastard to get in and out. I've done it about six times but it still drives me to the brink of madness.
GC
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Bloody sexy so far(!) Keep on going, if only to make the rest of us feel guilty/jealous!!
Looking forward to seeing the finished result ;D
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Well probably not the most exciting thing to take photo's of,but the wiring is now finished.Repositioning the battery to its new location under the tail piece and moving and hiding various electronics under seat required a bit of alterations to the loom and some longer battery cables to be made.Well I could of used bits of wire knocking around in the shed and some of them horrible plastic covered crimp on connectors,it would work,but its too much of an obvious bodge and anyway it was straight forward and cheap enough to use the correct colour coded wires and soldered on connectors .I got all wiring and bits of this sitehttp://www.vehicle-wiring-products.eu/ (http://www.vehicle-wiring-products.eu/)
battery in its new location
(http://i491.photobucket.com/albums/rr277/cloda12/w2.jpg)
electronics zipp tied to a aluminum plate (a piece of an old road sign liberated from a skip).
(http://i491.photobucket.com/albums/rr277/cloda12/w1.jpg)
Couldn't resist doing a quick mock up to give you some idea of what I am trying to achieve
(http://i491.photobucket.com/albums/rr277/cloda12/mock1.jpg).
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All of you who have owned a XBR for any length of time will be well versed in this weeks episode, namely sorting the front brake.Naturally mine was partially seized,so this entailed stripping down the caliper.I took the caliper to work so I could use the compressor to force the pistons out,after a good clean up,new pistons and seals were fitted .Next the sliding pins were cleaned and refitted coated with silicon grease,pads were all good,so it all went back together again ,with some black VHT paint on the exterior to finish the job off.
(http://i491.photobucket.com/albums/rr277/cloda12/brake1.jpg)
After cleaning out the master cylinder,I fitted everything back on the bike and connected the system using a s/s braided hose.Bleeding the brakes was a bit troublesome,I ended up connecting a syringe to the bleed nipple to drew the fluid through the system,took a few goes until a firm lever was achieved.
Fitted my customized sprocket cover :)
(http://i491.photobucket.com/albums/rr277/cloda12/sproc2.jpg)
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Aha, the (in)famous "TT" sprocket cover, a special fitment to all of the Hurley-Pugh Isle of Man TT entrants for the 1922 races. The cover was, as we all know, discontinued after the unfortunate accident that saw Lyndon 'Gnasher' Montcrief completing the final lap of that year's Senior with only three toes on his left foot.
Despite the factory dropping the cover it became a badge of honour amongst sporting Hurley-Pugh owners to fit the 'TT' cover to their bikes and it was common to see machines with the "TT Sprocket Shroud" right up until the outbreak of the Second World War. As an aside, it was a standing joke that very few Hurley-Pugh riders were eligible for active service in WWII because of the injuries and disabilities (including missing toes) that they acquired through their choice of mount. A man's bike indeed!
GC
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Aha, the (in)famous "TT" sprocket cover, a special fitment to all of the Hurley-Pugh Isle of Man TT entrants for the 1922 races. The cover was, as we all know, discontinued after the unfortunate accident that saw Lyndon 'Gnasher' Montcrief completing the final lap of that year's Senior with only three toes on his left foot.
Despite the factory dropping the cover it became a badge of honour amongst sporting Hurley-Pugh owners to fit the 'TT' cover to their bikes and it was common to see machines with the "TT Sprocket Shroud" right up until the outbreak of the Second World War. As an aside, it was a standing joke that very few Hurley-Pugh riders were eligible for active service in WWII because of the injuries and disabilities (including missing toes) that they acquired through their choice of mount. A man's bike indeed!
GC
Well in my defense I refer to page 6,paragraph 4 ,sub paragraph 3 of the 1922 Hurley-Pugh TT operatives manual,namely;
"It is imperative that all operatives wear the regulation issue, elephant skin,otter fur lined, boots at all times".
Still, dear old "Gnasher" didn't let the loss of a few toes stop him,I heard he took on the gainful employment of a young athletic boy servant to kick start his motor every morning.
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I hadn't heard that story about 'Gnasher' and his boy, but given the books he wrote (under the alias 'Geoffrey Prout') it comes as no surprise that he liked the company of young and healthy boys.
(http://cache.virtualtourist.com/2168585-Travel_Picture-THE_INNOCENCE_OF_EDWARDIAN_ENGLAND.gif)
GC
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All this talk of ' Gnasher ' and his written work , rekindled fond memories of the activities of his younger sister , Amelia ' Spanker ' Montcrief .After a colourful education ,' Spanker ' took to writing a number of small books on 'Home economics'. Many of these became standard reference works on the subject. Her 1921 publication entitled ' Short hints for Washing day ' gave the following advice for Mothers who are dealing with dirty linen ;
" If clothes are very dirty ,add half a teacupful of parafin to a copperful of clothes.This must be added to the water .Before doing so ,please ensure that one's pipe is extinguished "
Sound advice indeed .
She followed this is 1923 ,with her reference book entitled ,' Insects and how to manage them '.Regarding ants in cupboards , she advised ;
" The only sure method of getting rid of ants is to catch and kill them .Set in the closets ,plates coated thickly with soft lard , with little sticks leaning against them for the ants to climb . When the lard is covered with ants,drop it into a pan of boiling water,and then repeat until the entire colony is eradicated for ever ".
She clearly had an ordered brain , far ahead of what was considered the norm ,back then .
' Spanker ' used a percentage of monies earned from these publications to carry out good works with retired clergy and actresses and her pipe smoking figure was a familiar sight in many exclusive establishments .
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I can't help but notice, Hurley, that you have chosen 'Gurnos Grey' for your frame colour. Given its one previous use on the 1938 show bike (see details HERE (http://www.hurley-pugh.co.uk/mcdisast.html)) do you not think you are tempting fate?
GC
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I can't help but notice, Hurley, that you have chosen 'Gurnos Grey' for your frame colour. Given its one previous use on the 1938 show bike (see details HERE (http://www.hurley-pugh.co.uk/mcdisast.html)) do you not think you are tempting fate?
GC
'Gurnos Grey' is indeed the rarest of hues,discovered by the very short lived artistic director of Hurley-Pugh motor works,Sir Percival Gaytrousers who was immediately dismissed for being a reactionary modernist,and the Hurley-Pugh range of machines reverted back to the classic colour range of; Anthracite,midnight,very dark Grey and of cause Black.
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Hurley ,
Can you assist. Trying to track down an orginal manuscript for Capt Eric 'Killer' Steerforths technique ,' Re-invigorating posterior circulation ' .
I am planning a number of long trips and this may come in useful ,post ride.
Rob .
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Ahh remember when reading this he had an Indian Sepoy runing behind to carry out some of the more - ummmm - interesting techniques. You may find in the current climate a Sepoy is financially disadvantagous
R
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Hurley ,
Can you assist. Trying to track down an orginal manuscript for Capt Eric 'Killer' Steerforths technique ,' Re-invigorating posterior circulation ' .
I am planning a number of long trips and this may come in useful ,post ride.
Rob .
Indeed,a most invigorating if somewhat protracted exercise,perfected by the good captain during a lengthy stay in Morocco between the wars.I believe reprints of the manuscripts including some rather lovely etchings are still available at certain 'specialist' book shops.
I feel I must leave you with a dire warning,this sort of malarkey is really for the younger fellow,a warning not heeded by an aged steerforth who sadly perished whilst trying to perform said manoeuvres.
Had to bury the poor chap in a L shaped coffin.
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Thank you Hurley . My well thumbed copy is now showing signs of distress .I am currently researching information which suggest that a chance meeting occurred between Capt Steerforth and Amelia 'Spanker 'Montcreif at a works outing to the Henley Regatta in 1932.It appears that Miss Montcreif had spent the day seated on her hunting stick and 'Killer' had proffered his assistance with regard to a circulatory problem unexpectedly suffered by 'Spanker'.
I will update you .
Rob .
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This has long since become a rant, hasn't it?
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Well back to business, after recent thread hijacks ;)
The exhaust has been refitted,along with the cleaned up carb.I'm running the bike without the airbox so I upped the main jet to #165 and fitted a performance air filter.
Anyway the bikes outside now and whats more started at the first attempt :D
Needless to say I had to spend half an hour sorting out various exhaust leaks.
The bike seems to idle well,but its not legal yet to test ride,I suspect I may have to mess with carb to get to run 100%,oh,and yes I did fit a crankcase breather filter.
This is my only bike and I'm itching to ride it, so I may well leave the painting for the time being ,which just leaves me with a few jobs to sort for the MOT.
I'll post some pics soon,SWMBO decided she wanted to go out and take pictures of trees and flowers today ::)
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Still can't believe how quick you've done it, mines still in pieces...
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Piccies Please ,Hurley .
Rob .
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More pics, More pics!
Can you go through how you cleaned the engine up again?
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Is this the time to mention that my café racer project is approaching its 20th year and I'm still not finished...
GC
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Sorry I know Iam well overdue a progress report,but it's kicked off big time at my bike shop so Iam working all the hours at the moment to keep up,always the same abit of sunshine and thats my sparetime gone ,still good to be busy.So apart from gazing forlornly at my machine all i've managed to do in the last two weeks is fit a number plate :o
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20 YEARS!!!! - ahhh you have a time to go yet!!! LOL
Oh should this thread have a rename, is not really a Newbie anymore
R
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I grabbed a few minutes today to post up some new pics
(http://i491.photobucket.com/albums/rr277/cloda12/xb72.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xb77.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xb93.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xb66.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xb67.jpg)
Still loads of (hopefully) little jobs to be done to get it legal and running right,but aesthetically I'm pleased with the way it's turned out,proportionately its much better balanced than a standard XBR at least to my eyes ::)
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Good work that man ;)
GC
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So after 300 miles of "test riding" I decided to be a good citizen and take the bike for its MOT.I must admit to being somewhat anxious about this,fully expecting an autopsy of sorts.Of cause I needn't of worried,passed first time ;D.
So that's me done for the time being ,back to what its all about,riding,and must say my 'new' XBR caff is vast improvement on my old XBR hack,everything feels tighter,the brakes are much stronger (I can get the rear wheel to lock up now,for the first time ever),powers up a bit,handling's a lot more inspiring ,and even the new riding position suits me better.
As always there's still some finishing to do,like the paintwork, though I'm really getting to like the bare metal tank :).Also ideas in the pipeline;dommie/XL exhaust,different tank,removing electric starter,600 cylinder/piston,and spoke wheels...........watch this space ;D
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More pics for you.
(http://i491.photobucket.com/albums/rr277/cloda12/xbr2005.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xbr2008.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xbr2009.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xbr2011.jpg)
(http://i491.photobucket.com/albums/rr277/cloda12/xbr2013.jpg)
"does my bum look big in this?",well problary,but kinda offsets the "beached whale" tank pretty well.I posted some pics of the bike on a US cafe racer site,they loved the comstar wheels ;D
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That's bloody ace, well done that man ;)
GC
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thats looking good, i wish mine was roadworthy by now!!