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Author Topic: Excess Four Hundred (XS400 Brat Build)  (Read 5139 times)

Offline Rusnak_322

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Excess Four Hundred (XS400 Brat Build)
« on: May 13, 2017, 18:02:33 »
About time I started a build thread for this bike.

This one is for my wife, she has a vision of what she wants. Happy wife = happy life.

Here is her inspiration



She wants it flat blue tank with tangerine wheels.







Here is the blue that I am thinking of, with a matte clear. I plan to paint it myself.



Here is a powdercoat color that we are looking at for the wheels. I wouldn't mind a little orange elsewhere on the bike to tie it in with the wheels, but I can't think of what else to coat.












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Offline Rusnak_322

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Excess Four Hundred (XS400 Brat Build)
« Reply #1 on: May 13, 2017, 18:14:55 »
This is what we are starting with.
 




She wanted a disk brake and I think mags will look cool, so I bought a parts bike for $80 and made the swap.


















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« Last Edit: May 13, 2017, 18:16:42 by Rusnak_322 »

Offline Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #2 on: May 13, 2017, 18:31:12 »
The plan is for a flat seat with a short rear fender.














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Offline Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #3 on: May 13, 2017, 18:41:12 »
Cut the frame today.






And making a seat hoop. There isn't a off the shelf hoop that I can find that will work with the XS and its wide hips. It isn't a standard die size for tubing benders. So I made my own.





Used a router table with a 7/8" cove bit



Glued and bolted together, added a bushing and a strap to hold the tube.












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Offline Rusnak_322

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Excess Four Hundred (XS400 Brat Build)
« Reply #4 on: May 13, 2017, 18:42:13 »
Filled the tube with play sand and welded bolts to the ends.















That is where I am at. I need to come up with a way to bend the hoop to match the seat.

I also picked up everything we need to convert the rear 16" rim to a disk 18". That will allow better tire selection.






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« Last Edit: May 13, 2017, 18:46:04 by Rusnak_322 »

Offline Ant36

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #5 on: May 13, 2017, 22:04:15 »
Nice build I like the wooden dies for the homemade bender! Very creative!


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1980 CB750F

Offline Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #6 on: Jun 02, 2017, 18:59:28 »
Anyone have a newer Ducati Monster? My wife is really wanting to have the Monster headlight on her bike.




I think that it may be too wide. The nearest Ducati dealer is over 1 hr away. I know that the mounting will be difficult, but I think doable as they bolt to the lower triple on the 696.

Has anyone ever come across a similar aftermarket light? A used Ducati light is going for $200-ish on eBay, so they ain't cheap.


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Offline canyoncarver

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #7 on: Jun 02, 2017, 22:00:31 »
Nice bender.  Well done.
--
YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
The Shovelhead springer chopper
A bunch of KZ's...some Suzukis', and a disassembled CB550
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Offline Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #8 on: Jun 21, 2017, 21:12:29 »
Finally got around to finishing the frame hoop bending.

Made a jig to hold it and some buck to bend against.

I got a small crimp, but the way the seat sits, it won't be seen.

If I were to do it again, I would have welded pipe with a ID closer to the tube OD and even though I made the bucks to account for spring back, I guessed too little.
















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Offline Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #9 on: Jun 21, 2017, 21:34:51 »
Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating






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