Time for the build thread: XL600 Tracker

Hey all,

It is finally time for me to document my build.

After gaining inspiration from Cafe Racers Dreams, CRD19 "Apollo". My quest for a donor bike began



In Wisconsin, a bike that isn't titled originally, can't be titled for the street. So instead of an XR600, I had to look for it's street legal predecessor, an XL600.

While surfing Craigslist, I happened across this beast for $1000. I had an exact budget of $800 for the donor itself. After insisting, I'd walkaway at $800, I loaded up the bike and I was off.



I tore the carbs off and got the bike running and riding. I cleaned up nice with the assistance of an ultrasonic cleaner. The bike has about 10,000 hard ridden miles on it. After reassembling the carbs, it starts on the 1st or second kick. Not bad for a bike that was build one year after my birth.



A few months of head scratching and planning. I tore into the bike.

I started by stripping the bike down to its frame.



After her clothes were off, out came the angle grinder equipped with 3" cutting wheel. Subframe no more!



After grinding the remnants of the welds, the fun would begin on constructing the new subframe. I enlisted help from a professional welder I met at a maker's space and we went to town with cutting the tubing to length. I purchased a pre-made hoop off of ebay and build the subframe around it.




The gratoutious grinding shot. Notice Mike wearing the grinding shield and glasses? Safety first, kids.


I picked up the ubiquitous CG125 tank for a build of this type. Not too shabby for a dude that's never tackled a project like this.


We welded in the seat mounts to the sub.




I started by making a template out of cardboard then poster board for the seat pan.



I picked up a slab of 22ga sheet steel and used one factory edge of the sheet metal as a straight edge. I then used the cut-off wheel on an angle grinder to cut the other side. The curve was a series of straight cuts. (Glad I got my tetanus up to date). Then off to the bench grinder to round out the curve. Not bad for some basic tools.



Continued...

I am in..

And now onto building the seat.

This is the desired outcome.



I picked up some carpet padding from Menards and went to town. I'm not sure how well it will mold as far as cutting and sanding.


What does everyone else use for this? Different foam? I'm going to try a "cheese grater" or a shaving plane.

Most folks use Neoprene foam, or a similar high density closed cell foam.

http://www.diymotorcycleseat.com/foam_types.htm

If you hit that carpet padding with a grinder its gonna get screwed up fast...it will probably just grab it and throw it across the garage..

I'm in, looking good so far. Thanks for sharing

I tried hitting it with a grinder and a flap wheel. It wanted to buck. It didn't fly across the garage, but it did gouge it.

I think I'll try the closed cell route. Thanks for the link, JustinLonghorn!

I emailed Ginger at New Church Moto. She is willing to do the foam and upholstery. I might swallow my pride and just go that route. She does fine work.

http://newchurchmoto.com/gallery.html

This looks like an interesting project.

I used 80 grit paper to smooth n shape foam to very good effect on my seat. You'll be surprised how well it takes the foam off.

Liking the build! Where in Wisconsin are you? I grew up in Rhinelander. In Milwaukee now!

Looking so good already man! Good idea to enlist a pro welder for the subframe - especially cos it is so structural and load bearing. Following this one!

@knitt31, I'm in Madison. PM me if you ever make it up to The Crud Run.

Originally from Rapids. Me and my pops are in the process of building a small cabin just south west of Rhinelander.

I'm in the process of doing a custom seat as well.
I found this to use as a base: https://www.austinkayak.com/products/1137/Closed-Cell-Foam-12in-x-24in-x-12in.html
And this for the upper soft padding: http://www.joann.com/airtex-foam-chairpads-2in-high-density/3619228.html#q=High+Density+Foam&start=1

You really can't beat those prices for a diy'r.
BTW, like the build.

Thank you, alzcbz. I'm weighing all my options.

Solid

very promising project!

More fab work. The 83 XL600 didn't come with a rear disc brake. This process has already been fun. But the end result will be worth it.

So, now for mapping and fabbing a master cylinder hanger bracket.

The concept:

I used a master cylinder I found on ebay. I liked that the reservoir was combined into the cylinder so no hose to run and no extra brackets. This should do the trick.

Pattern transferred to steel and holes drilled.


After a little clean-up work on a bench grinder.


Mocked up. Also. Note the additional bracket welded on to the brake pedal.