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Author Topic: Excess Four Hundred (XS400 Brat Build)  (Read 1619 times)

Online 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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Online 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 »

Online 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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Online 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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Online 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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Online 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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Online 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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Online 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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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #10 on: Jun 21, 2017, 21:38:37 »
Also - picked up some tires.







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Online Rusnak_322

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #12 on: Jun 22, 2017, 13:28:21 »
Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating






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My research came up with a problem.
Looks like the rubbers are cast into the wheel and there don't seem to be replacements available.

Anyone ever seen this before? Looks like RD parts are too short to work on the XS wheel.




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Offline irk miller

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #13 on: Jun 22, 2017, 14:20:32 »
They remove with heat.  You can see the metal tube the urethan is cast into.  It comes out of the wheel.  Not too hard to recast from a 2-part urethane if you need to.  I converted a rear drum brake wheel to disc by machining a hub to hold the rotor and casting it into the rim with urethane, so it's essentially just like a cush drive.  That said, maybe it's not worth the effort to powder.  You can always use an automotive paint with a 2k epoxy clear coat. 

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Re: Excess Four Hundred (XS400 Brat Build)
« Reply #14 on: Jun 22, 2017, 20:30:04 »
Yeah, I am leaning that way. I can paint myself, and the powder quote I got was $125 per wheel. I can pay to have them blasted and but the paint for the cost to powder 1 rim.

Just trying to decide if it should paint B4 or after I mount the tires. I would hate to have it ruined when spooning on the tires.


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