My XBR project

[JOOLZ]

The cx tank looks in reasonable condition, give it a coat of tank sealent to be extra sure before you use it, (mine had a few pinholes and alls been fine for 8+ years) Those are a good set of downpipes, the copper seals are pretty much a one use item so will always need replacing.

[iansoady]

I'm a bit wary of tank liners having heard some horror stories. The Francis Barnett I rebuilt a year or so back had some awful resin like stuff inside - but floating about loose. It was the devil's own job to get it out as some lumps were too big to come through the filler hole & I had to use a hacksaw blade to cut them inside. Horrible.

[mthee]

That's the old stuff. POR15 system is an easy 3 part, modern system - degrease, etch and seal. I've  used it and all is well on the CB200 tank which was really rusty.

[iansoady]

Hopefully will be getting that tank this week so will check it out carefully.

[iansoady]

Cracking on...

Bits arrived from David Silver so fitted oil filter and plug - I ended up turning down an old 3/8 drive one si it fitted in the narrow gap. Filled up with 10W/40 semi-synthetic.

Checked the VF400 bars to be sure they'll fit - they'll be about 45mm higher and 40mm further back. I think the cables will reach except maybe the choke so I may have to make a new one. Gave the bars a couple of coats of wheel paint which gives a nice silver colour.

Also started to attack the broken clip on the side panel. Flattened off the face and drilled 3/8". I'm now making a delrin part to mimic the existing one.

Bars as they were:



Painted:





and:





Clip position drilled 3/8":





and what I'm trying to replicate:

[xbally]

Sounds as though you have got lots to occupy you in the coming months before the better riding weather hopefully returns.

[mthee]

I knew I was going to enjoy this thread - good quality workmanship and photos to match   

[iansoady]

Turned up a replacement clip from a bit of delrin I had lying about and glued it in using superglue. Will it work? Don't know but worth trying. I may have made it slightly undersize as it was tricky to measure. Measure once make 3 times.....

[iansoady]

And here are the repainted VX400 bars installed. Everything fitted very nicely except the choke cable which I will have to remake 3 or 4 inches longer. It's an awkward thing though. The bars look as though they were made for the job.

[Moto63]

Result Ian... fingers crossed the nylon lug holds out with the super glue🤞. Certainly looks good 👍

[iansoady]

Seat arrived from a nice chap on the FB pages - just what I needed. I think I will mod the base myself but get someone more expert than I to modify the foam and make a new cover. I need to get rid of the kick up at the front and get it reshaped to remove the step and get something like a straight line along the top. I got a replacement seat to fit in with my idea of making reversion to standard a simple job.

But I can't move forward till the tank arrives, which I've agreed to buy but need to organise carriage. Nobody here in Eastbourne I don't suppose?

[mthee]

Are you going for the same classic seat as the German bike  Rossco500 posted up?

[iansoady]

My initial feeling is to keep the tailpiece as that simplifies mounting (and also avoids making any structural changes). But the idea is to remove the step, chop the front off to (almost) meet the tank and have a cover made. That should achieve a nice clean line.

Eventually have agreed on the tank and will need that before I go further. But I did pop down the classic bike shop just down the road and bought some Lucas pattern indicators and a Goldie pattern silencer.

[SteveC#222]

Aye Ian,

Predator Motosport are producing reproduction sets in stainless steel, at a price!    But cheap in terms of man hours faffing about! Link to Predator site below.

Honda-XBR500-repoduction-exhaust-clamp-in-s-steel-each

Good health, Bill

I've got some on mine and can recommend them ( Yes they are pricey!!)

[tommy]

those bars look great ian nice work your doing on this xbr ..tommy