My XBR project

[Moto63]

Looking good Ian, bet you’re chomping at the bit to get back in the garage eh. I know I would be. Look forward to the next instalment of pics.
Cheers, Michael

[iansoady]

Yes, when my back's recovered after struggling with the back wheel...... I do wonder why Honda and other manufacturers didn't adopt the QD arrangement like the Norton Commando one. Remove the spindle, drop the spacer, slide the wheel sideways and out it comes, leaving the chain and brake all connected up.

[Itsme]

Looking good there, I can see how it is going to change with the CX tank and the other things you are doing. I do like the original XBR tank, I always felt it fitted me well, but I also really like individual bikes that the owner has made their own. Starting to take shape and I would be really impatient to get out and start riding it, which probably explains why I never finish a job properly!

Glad the wheel straightened up ok, that's another job ticked off. So looking forward to the next bit of progress.

Other Ian

[mthee]

The only issue I can see at the moment is the petrol tap wants to be in the same place as the side panel. Maybe I can get it moved?

Needs a new petcock bung and hole drilling. I trotted off, tank and bung in hand to a local shop where matey closed the old hole and welded in the new bung, similar to this one;

https://www.ebay.co.uk/itm/401082725021?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=C8p19QcbT0O&sssrc=2349624&ssuid=GT0R2p0dRG2&var=&widget_ver=artemis&media=COPY

Lots of different taps to choose from at this stage (before turning the bung yourself?)

Thanks for the pics and great commentary 👌

[iansoady]

Ooh, they're expensive! I was thinking cut out a square around the boss and get the welder to weld that in to a similar cavity further forward which I can cut with the angle grinder. Fortunately there is a nice flat bit where I'd want the tap to go. The tank is actually in very good condition and will get it blasted soon so I can make any adjustments. I think I will make some eccentric bobbins out of black nylon so I can make sure the front of the tank is well supported as it's only halfway on as it stands - and the forks are kissing the front of the tank on full lock. Hopefully eccentrics will let me drop it a bit and move it slightly backwards.

I offered up the RH side panel with the tank in situ and while it doesn't line up perfectly I think I can see how it will look.

I think I will slow down a bit while I consider options. I've only had it for 2 weeks!

[mthee]

Good idea about the bung, given as you say, all that available  space. Ideas are obviously flowing and I hope you are as much as a pig in the proverbial as I was!

[iansoady]

Just waiting for some disaster to occur.

I've been looking at the badge fittings - I don't want to use the big Honda badges as the CX would have had but a wing decal as on the XBR. The fixings seem to be spot welded to the tank in a recess but are a bit proud of the surface so will try to flatten them off using the angle grinder then fill back to a nice profile. I can't see how to remove the spot welds without the danger of damaging thetank underneath.

I've also been looking at removing internal rust - it's not bad but there is some - using electrolysis as in this article: https://www.classicbikehub.uk/Workshop/article/petrol_tank_rust_removal. I can't decide whether to do that before or after blasting the outside.

[mthee]

How about a Dremel style of tool for tight spaces? You can get mini grinding wheels for them or stones of different shapes.
I don't  suppose it really  matters about the order, but I'd  go for electrolysis first (can get messy, but might just be me)
Also, if you plan to seal the tank, that can also be messy. Here's  my go and some good advice from members;
http://www.thumperclub.com/index.php?topic=9541.15

[iansoady]

Obviously I'm following in your footsteps Matt! I'll give the elctrolysis a go and have some soda crystals on their way. I think I will go for electrolysis then blasting then moving the petrol tap - if blasting reveals any holes I can get them welded at the same time. Yes, I have a dremel and will use that for the fine detail stuff. I must admit using angle grinders always scares me to death. All I need to do is get the retaining plates below the surface level of the tank.

I made up an oxalic acid solution a couple of years ago and tried it on rusty bolts - it did seem to clear the rust but left a strange green deposit. And it's apparently very toxic - watch out you rhubarb eaters.

Off to a paint matching place in Bromsgrove today with a side panel to get some paint & lacquer aerosols for the tank. I know it won't be petrol proof but my experience has been that once throughly dried the odd splash of petrol isn't a problem.

As a small experiment (and slightly off topic) I have used JB weld to stick 2 bits of mild steel together and left that submerged in a jamjar full of petrol for a week. The bond seems to be standing up but some of the excess has gone soft.

[Itsme]

I am always in awe of people who cut holes in petrol tanks, to me the skill level required to weld them back together is an inconceivable skill level to attain. I lack not only the skill, but also the confidence to think about making a perfectly leak-free petrol tank into a sieve! Glad there are people who will take on the job though.

Spartacian the amazed.

[iansoady]

My welding skills are virtually non-existent - quite apart from the fact I sold my Mig welder some years ago as it was just collecting dust under the bench. I'm quite happy to cut holes and let other people weld them up again however. There's an excellent specialist welder just round the corner from me.

[Moto63]

Ian. You could always cut the bottom of the tank out, that way you can get to the inside to grind any rust out. Plus then, when you get your expert welder friend to weld it back together you can move the petrol tap position to suit at the same time. Just a thought 🤔
Cheers...Michael

[Moto63]

I am always in awe of people who cut holes in petrol tanks, to me the skill level required to weld them back together is an inconceivable skill level to attain.

Spartacian the amazed.

Well being a fully qualified city n guilds plumber I can do your shower base and surround AND tig weld your petrol tank if so required. We can discuss my hourly rate at a later date 🤪😉😉
Michael.. the inconceivable

[iansoady]

TBH the tank isn't that rusty (he said hopefully) so I think I'll limit the amount of cutting and shutting necessary.

[Itsme]

Michael

How did you know that my shower base needs replacing!! You have two more useful skills than me there, I could make you a bracket which will fit where it touches and have at least one hole in the wrong place.

Mind you if you ever find yourself needing to be fed or medicated via a Percitaneous Endoscopic Gastrostomy I'm your man!

Spartacian the impractical but caring.