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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: JAGspeed on Dec 20, 2013, 21:48:56

Title: Cafe XV920R Mega-Build
Post by: JAGspeed on Dec 20, 2013, 21:48:56
 So I finally got around to my XV920R project. I picked this bike up last year, but got sidetracked with my XS650 Tracker build. Just finished that one a couple of weeks ago. Now I can focus on this build. I have a lot of plans for this build so it could take a while, plus I need to out do my last build.
I want to try and build my own frame for this bike. I am going to use a modern front end ,swing arm and shock. Plan on some motor work as well, so I have my work cut out for me. Here are a couple of pics of what I am starting with as well as the bike after tear down.
Title: Re: Cafe XV920R Mega-Build
Post by: Rich Ard on Dec 20, 2013, 21:50:45
In, because I subscribe to every Virago project, god help me.

Are you going to use that tank? Why that one didn't go on all of the bikes of that generation I'll never know.
Title: Re: Cafe XV920R Mega-Build
Post by: beachcomber on Dec 23, 2013, 06:57:06
In, because I subscribe to every Virago project, god help me.

Are you going to use that tank? Why that one didn't go on all of the bikes of that generation I'll never know.

yes, us TR1 / XV / Virago builders have to stick together !!!!!!!!! The only way I can steal good ideas.

I toyed with the idea of a modded BMW K100 trellis frame, together with a telelever front end - would fit without too much aggro - but that was one of the projects I had to cull back in the Summer.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 12, 2014, 01:51:25
Found Me a front end. Courtesy of an 08 CBR600RR had to do some mods to the steering stem to make it work. Still need to hunt down lots of stuff before I start fabing things up.
Title: Re: Cafe XV920R Mega-Build
Post by: Cuba Libre on Feb 20, 2014, 03:59:25
In, because I subscribe to every Virago project, god help me.

I'm in too - probably for the same reason...

M.
Title: Re: Cafe XV920R Mega-Build
Post by: HollywoodMX on Mar 16, 2014, 18:46:20
If you need any help, let me know.

I went the motor route and knee deep in it. If I was to do it again I would have skipped out on doing the motor but it's too late now.
Title: Re: Cafe XV920R Mega-Build
Post by: bananas on Mar 16, 2014, 19:09:53
Love those Vtwins! Pretty sweet front end. Is it painted or did it come black?
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Mar 16, 2014, 23:35:36
Love those Vtwins! Pretty sweet front end. Is it painted or did it come black?

The front end came black, I specifically wanted it that color.  Still gathering up several other components for this build. I think I spend as much time searching E-bay as I do working on this bike.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 17, 2016, 22:35:11
Well if your wondering what happened to this build it got put on hold for a while for other projects and work. So I finally back on it again.
I have collected some parts for the build while it was sitting. I decided to use a RC51 Swingarm, wheels and rear suspension.
I mounted the bike in my frame jig and started sizing things up.Since I am building my own frame I decided to try and get a much better geometry for handling. I am going to try and get the front swingarm pivot as close to the countershaft as possible as well as get a pivot height that will work better to improve anti-squat characteristics. I will also give the swingarm more of an angle which will require me to raise the motor in the chassis. I removed the frame and sized up the RC51 swinger. Just need get it as close as possible and them do all the math to make sure it is correct.
Title: Re: Cafe XV920R Mega-Build
Post by: canyoncarver on Jan 18, 2016, 15:27:42
This should be pretty wild.  I'm glad you are getting back to it.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 21, 2016, 23:43:14
I wanted to find a way to give the new swingarm more support rather than just the original mounting point off the back of the engine since the RC51 swingarm is much beefier and I will be running a 190 tire on it. I devised some mounts out of wood for mock up that utilize the stock peg mounts and support the outside of the swingarm. I used the original frame mount and made a center piece to locate the swingarm closer to the countershaft sprocket and give it a better alignment for the pivot point. I also raised the engine for a better swingarm angle. The new mock up pieces will serve several functions (1) Swingarm support (2) top shock mount (3) sub-frame mount (4) foot peg mount, and (5) Counter shaft outer bearing support. It took some time to get it all sorted but it looks like it should work really well. I will have these pieces made out of aluminum on a CNC.
Title: Re: Cafe XV920R Mega-Build
Post by: slikwilli420 on Feb 22, 2016, 10:13:03
Pretty good looking build so far. As to your new brackets, you could have them cut with water jet for a fraction of the cost of CNC mill and then hand finish them yourself. I have done a ton of parts that way and its substantially cheaper.
Title: Re: Cafe XV920R Mega-Build
Post by: treitz on Feb 22, 2016, 12:23:08
Damn this is going to be cool. Love all the custom frames popping up lately. Gives me something to aspire to.
Title: Re: Cafe XV920R Mega-Build
Post by: Karlloss on Feb 22, 2016, 14:31:52
In, because I subscribe to every Virago project,

Me too, every XV project on here has me watching!
Title: Re: Cafe XV920R Mega-Build
Post by: mazza on Feb 22, 2016, 15:57:54
Dito
Title: Re: Cafe XV920R Mega-Build
Post by: cole.pinnow on Mar 16, 2016, 04:33:33
same.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 12, 2017, 13:00:11
Back to it. Finally found some time to get back to this build. I designed my parts in a cad program and had my CNC guy cut them out for me. I finished the rear mount that supports the swing arm and is also the mount for the rear suspension. The CNC parts fit great and should add a lot of strength to the rear end.
Title: Re: Cafe XV920R Mega-Build
Post by: Stribolt on Feb 12, 2017, 13:36:44
Nice fabrication skills !


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Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Feb 13, 2017, 01:16:35
Looking great! Don't let it fade into obscurity - this looks like a good one that I would like to see finished.
Title: Re: Cafe XV920R Mega-Build
Post by: Virago1113 on Feb 17, 2017, 19:00:23
I'm definitely in on this one.

The custom work is very impressive! Can't wait to see the end result.

My question is, will there be room for the rear exhaust pipe?
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 17, 2017, 23:57:09

My question is, will there be room for the rear exhaust pipe?
The exhaust will be  a bit of a challenge but there is room for it. The RC51 swing arm I am using has the shock offset to the right and there is a space beside it where the stock RC pipe came through. So I will be able to come through it to do my exhaust.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 18, 2017, 00:15:32
Frame is almost done. I used box tubing to make the main part of the frame and welded it to the stock head stay. I designed and had two support plates cut out to box it in. The plates will attach to a custom bracket mounted to the head similar to stock. I had my frame come down closer to the head for more support. I also will be securing it with 3 bolts instead of 2 like the original. I did move the steering head stay closer, lower ,and at a more aggressive angle than stock for improved handling. Need to finish up the welding and make my mounts to the engine and she'll be a roller.
 
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 28, 2017, 00:08:56
Doing some more work on the frame. I made the mounts that goes from the heads to the frame and finished most of the welding. Still going to add a couple more supports, but now I should be able to make it a roller pretty soon.
Title: Re: Cafe XV920R Mega-Build
Post by: BillyGoat4130 on Feb 28, 2017, 09:34:28
Really like how you scratch built the back bone and neck on this bike, very nice work!
Title: Re: Cafe XV920R Mega-Build
Post by: jcw on Feb 28, 2017, 12:34:59
Not planning on connecting the rear frame and the top frame together?
Title: Re: Cafe XV920R Mega-Build
Post by: doc_rot on Feb 28, 2017, 15:39:42
are you going to bore the headstock bearing cups post weld? I have been thinking about making my own swing-arm lately and one of the issues I've been scheming on is how to fixture the swing-arm to bore the bearing cups after welding to eliminate distortion. nice work.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Feb 28, 2017, 23:48:21
are you going to bore the headstock bearing cups post weld? I have been thinking about making my own swing-arm lately and one of the issues I've been scheming on is how to fixture the swing-arm to bore the bearing cups after welding to eliminate distortion. nice work.
I took some precautious when welding around the headstock. First of all I left the bearing outer race in the headstock to help keep the shape. I also used welding gel on the race to help dissipate the heat. I doubt that I will need to machine it.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Mar 01, 2017, 00:04:46
Not planning on connecting the rear frame and the top frame together?
I am planning on connecting the top of the frame at the back of it to a point on my CNC parts, but I am going to wait until I get the tail section and exhaust figured out first so my mount won't interfere.
Title: Re: Cafe XV920R Mega-Build
Post by: GoCrazy on Mar 01, 2017, 05:27:01
Nice skills, I am going to visit here more often  :)
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Mar 18, 2017, 01:35:23
I was able to make it a roller. I put the 08 CBR600rr forks back on the new frame but ended up using a CBR929 Triple clamp to get the correct brake caliper spacing for the RC51 SP2 wheel. The disks are 08 CBR600RR. The rear RC51 SP2 wheel was of course a direct bolt on to the RC51 swingarm. Hopefully this will keep me more motivated.
The next step is to figure out my tank and tail section I have several ideas just need to decide.
Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Mar 18, 2017, 12:08:02
Absolutely wonderful work. Good luck choosing a tank - with that narrow backbone, the possibilities are endless...

What kind of clearance do you have under the oil pan with that setup?
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Mar 18, 2017, 21:52:57
Absolutely wonderful work. Good luck choosing a tank - with that narrow backbone, the possibilities are endless...

What kind of clearance do you have under the oil pan with that setup?
I have about 150mm of clearance should be OK. I also incorporated the ride height adjustment in my suspension design so I have the option of raising the rear a bit if needed.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 08, 2017, 00:48:08
Picked up a tank on Ebay from a BMW 9T. Really liked the shape of it ever since it came out. It had some minor damage but nothing to serious. I did have to do some surgery to the underside to make it fit and I will have to cap off the hole for the fuel injection and add a petcock.  It is an aluminum tank so there will be some TIG welding involved to make it work. The nice thing is there is plenty of room under the tank for the battery and all the electronics.   After I get in mounted I am going to work on my tail section.
Title: Re: Cafe XV920R Mega-Build
Post by: bikeWillem on Apr 08, 2017, 11:05:09
Awesome build! The tank looks really good and I think it suits the bike really nicely.  :)
Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Apr 08, 2017, 11:17:56
Woah. Wasn't expecting that at all. I'm picturing it with some motocross bars and the 9T scrambler subframe now...
Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Apr 08, 2017, 11:22:11
For a while on mine I was thinking of using an XSR900 seat, but there wasn't a way to cohesively line up the tank and the subframe it would require. It looks like it could line up with that tank really well. (They are also cheap brand new from places like motosport on the microfiche)
Title: Re: Cafe XV920R Mega-Build
Post by: SF on Apr 08, 2017, 13:56:32
Really impressed with the fab and detail. What welder are you using? Tank looks at home.


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 10, 2017, 13:32:37
Really impressed with the fab and detail. What welder are you using? Tank looks at home.

I'm using a Lincoln MIG welder so far because I am comfortable with it. I have access to a TIG but need some time on it to be able to run clean welds. I may try and TIG the tank myself, but I will most likely have a friend of mine that is a professional welder help me out.
Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Apr 15, 2017, 16:30:34
I have about 150mm of clearance should be OK. I also incorporated the ride height adjustment in my suspension design so I have the option of raising the rear a bit if needed.

I'm envious of your frame height it would seem then - everything I find lists the 08 600rr forks at 720mm fully extended and my 05 R6 forks are measuring 736 at ride height and I only have ~3" (76mm) of clearance right now.

Good work - I'm off to contemplate dropped triples, etc.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 16, 2017, 02:16:55
I'm envious of your frame height it would seem then - everything I find lists the 08 600rr forks at 720mm fully extended and my 05 R6 forks are measuring 736 at ride height and I only have ~3" (76mm) of clearance right now.

Good work - I'm off to contemplate dropped triples, etc.
The CBR forks are fairly short but are great units. I knew I was going to make my own frame so it was not an issue. I did move the head stock of my frame down several inches and back some to achieve the ground clearance I desired. The closer distance will also reduce flex in my frame and improve handling.
Title: Re: Cafe XV920R Mega-Build
Post by: Stribolt on Apr 16, 2017, 05:17:46
Taking my hat off 🤠 nice work


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 21, 2017, 12:04:22
Working on the tail section. I was able to make a subframe tail section out of tubing. It also ties the rear of the frame to the billet parts for added strength. I am going to add some pieces to the back of the tail section to fill it in. The muffler will run under the tail and exit at both sides of the rear part of it. This part is removable so I could make other tail sections later on to give the bike a whole different look.
Title: Re: Cafe XV920R Mega-Build
Post by: Luugo86 on Apr 21, 2017, 12:22:15
That's pretty solid man. I dig it, did you mig weld that all up? What size tubing did you use?
Title: Re: Cafe XV920R Mega-Build
Post by: JustinLonghorn on Apr 21, 2017, 12:34:18
You should leave the BMW emblems on it just to fuck with people.
Title: Re: Cafe XV920R Mega-Build
Post by: canyoncarver on Apr 21, 2017, 13:46:12
I love that tail you are building..    How did you get those bends?  Just heat or do you have a bender?
Title: Re: Cafe XV920R Mega-Build
Post by: SF on Apr 22, 2017, 00:23:52
F.... Ya!


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 23, 2017, 00:55:08
That's pretty solid man. I dig it, did you mig weld that all up? What size tubing did you use?
I did mig weld the subframe still have to finish up a couple of welds though. I used 3/4" tubing.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Apr 23, 2017, 01:03:06
I love that tail you are building..    How did you get those bends?  Just heat or do you have a bender?
I have a tube bender. I did have to weld several bends together in places because some of the bends were to close together and would not fit in the bender. I also used a press in a couple of spots to tweak some of the pieces to try and keep both sides symmetrical.
Title: Re: Cafe XV920R Mega-Build
Post by: Karlloss on May 02, 2017, 12:56:02
Awesome subframe assembly!


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on May 06, 2017, 23:00:04
Made a seat pan out of fiberglass. I taped everything off first and laid down several layers of mat. After it hardened I shaped it to fit. I'm sure I'll be itching for a bit, but happy with how it came out. Just need to add a couple of mounts then I'll glue in and shape the seat foam.
Title: Re: Cafe XV920R Mega-Build
Post by: woodsv on May 07, 2017, 02:51:07
Awesome custom work. This is what it's all about!
Title: Re: Cafe XV920R Mega-Build
Post by: der_nanno on May 07, 2017, 05:14:39
I do like the frame work!
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jun 09, 2017, 00:13:04
I did some more work on the seat. I glued in several pieces of foam and shaped it to form. I then covered it with a final thin layer of foam mat that helped keep it all together. I'll probably wait till I get closer to finishing the bike to get it upholstered so I don't have to worry about damaging it.
Title: Re: Cafe XV920R Mega-Build
Post by: hooligan998 on Jun 09, 2017, 01:02:17
Fashionably late, but I'm in!  Very nice work!
Title: Re: Cafe XV920R Mega-Build
Post by: Popeye SXM on Jun 09, 2017, 20:04:28
I 2nd that! great build, love the lines of the tank/seat/ subframe
Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Jul 26, 2017, 15:55:02
I hope this one didn't fade into obscurity. I have been liking where it's going.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jul 26, 2017, 20:20:16
I hope this one didn't fade into obscurity. I have been liking where it's going.
Just stalled a bit on progress haven't had much time to work on it lately. I did make some panels that fit into the sub-frame have a couple pics of that. I also started on my under tail muffler I'll take some pics and post that soon.
Title: Re: Cafe XV920R Mega-Build
Post by: dakine_surf on Jul 27, 2017, 08:53:41
Really like the way that's looking, great work.

I see all these virago build with tons of "go fast" bits like modern suspension etc... but what about the motor, I seem to remember them feeling lazy and wheezy (tractor or diesel like). I only rode one a couple times but i always felt the motor just didn't "do it" for me... I guess my question to you virago guys is more about what guys are doing to liven up the power and make it rev a bit more?


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jul 27, 2017, 11:19:45
Really like the way that's looking, great work.

I see all these virago build with tons of "go fast" bits like modern suspension etc... but what about the motor, I seem to remember them feeling lazy and wheezy (tractor or diesel like). I only rode one a couple times but i always felt the motor just didn't "do it" for me... I guess my question to you virago guys is more about what guys are doing to liven up the power and make it rev a bit more?

The virago motor makes a great street motor because it has a lot of torque. Never intended to race this bike but many guys have built the Yamaha TR1 to race which is essentially the XV920R. Same motor as the Virago only chain drive. There are several hop up parts for this motor, pistons, cams, carbs. I am planning on doing mods to mine.
Most guys that build Virago's just want something that looks cool and can ride on the street, plus I think this motor has a great look to it. But if you want more HP it is available at a price.
Title: Re: Cafe XV920R Mega-Build
Post by: dakine_surf on Jul 27, 2017, 11:29:10
Yeah I remembered it was good right off idle to about 3.4-4 and then just started to trail off and make more noise and not much else until about 6.5.

I sure some cams and more compression would liven things up a bit... I agree, it's a great looking motor especially with the modern suspension just "hanging" off either end


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Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Jul 27, 2017, 13:57:38
The panels are looking great. I was curious to see where you were going with that skeleton. Some bead rolling to match the tank could be interesting.

From putting a few miles on mine now I find what really woke this motor up is losing nearly 100lbs off the bike. I really like a low end motor too - I don't like having to rev the nuts off it just to move with traffic.

I wouldn't call it fast, but it's powerful and deceptively quick just up to illegal speeds. :)
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jul 28, 2017, 22:36:38
Finished the muffler. The can is a Two Brothers pipe that I shortened to fit under the seat. The tip was fabricated from 2 Mercedes exhaust tips a short piece of tubing and a couple of jigsaw pieces to close it all in.  I cut the tip off the muffler and made a mount that bolts it all together. Getting it all to line up was a bitch but worked out great. I am going to make a heat guard between the seat and muffler. Next is the exhaust system itself. I already know how I'm going to route it  just need to find some time to make it.
Title: Re: Cafe XV920R Mega-Build
Post by: Dr. Noisewater on Jul 28, 2017, 23:20:34
Looks very cool! Can't wait to see the rest!

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Title: Re: Cafe XV920R Mega-Build
Post by: advCo on Jul 28, 2017, 23:42:23
I'm just not sold on the muffler tips. The tail section looks great, but the split tailpipes makes it look cheap compared to the craftsmanship of the pipe and panels.

Maybe a single more subtle muffler would fit the bill. Or rectangular to mirror the subframe under the seat could be cool.
Title: Re: Cafe XV920R Mega-Build
Post by: stubsryan on Jul 29, 2017, 06:46:38
Looks awesome mate! This really is a mega build!


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Title: Re: Cafe XV920R Mega-Build
Post by: dakine_surf on Jul 29, 2017, 15:29:36
I'm just not sold on the muffler tips. The tail section looks great, but the split tailpipes makes it look cheap compared to the craftsmanship of the pipe and panels.

Maybe a single more subtle muffler would fit the bill. Or rectangular to mirror the subframe under the seat could be cool.
I agree, there is just something that throws my eyes...

That subframe is gorgeous, especially with the panels you made.  I think a couple tips that fill the space cutout for the exhaust tighter and more streamlined is the way to go... like a square box but contoured to flow with the curve of the tail.

As always I'm probably doing a terrible job putting this in words, I wish I had my drawing tablet to show you what I mean a little better.  That being said I love the direction you are going, keep it up, it's a great looking build


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Title: Re: Cafe XV920R Mega-Build
Post by: jpmobius on Jul 29, 2017, 19:27:32
I really like the dual exhaust outlets, but maybe there is a lack of visual flow that makes you do a double take to figure out if something is askew.  Seems odd since your fitment is so nicely done - a whole lot of work to get it to this point.  It is hard to tell from the pics, but perhaps the outlet tubes need to be more perpendicular in the vertical plane to the "surface" of the bodywork.  They look like they point down compared to the visual surface they "exit" from.  If you are keeping the factory baloney cut on the tips, it may be impossible to aim the tube right without having the skewed end looking wrong.  Also, with the outlets splayed apart at such a large angle the "Y" is super obvious being so close to the exterior of the tail.  This would not be a problem if you either fit a tail light between the outlets, or add/rework your tail framing to wrap around the back of the outlets like the front does.  If you look at how car exhausts look these days (they are often similar to your scheme with the tips "fitted" into the bodywork), they are usually parallel to the ground, and usually pointing straight back.  I don't think they necessarily have to point dead astern, but when relating them so heavily to the bodywork, they would seem to need to align with either a prominent body line (like the pitch of your rear sub frame) or the level ground to not look awkward.  None the less a lot of great work here - keep it going!
Title: Re: Cafe XV920R Mega-Build
Post by: SF on Jul 30, 2017, 20:17:55
Friggn looks great man! That will be an interesting sound also.


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Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Jul 31, 2017, 13:16:36
From what I remember about two bros, that is going to be loud. I prefer the 920 engine with a bit of muffling as when it's too open, you lose all of its very limited musical quality and it try's too hard to imitate a Harley without the lumpy character.

I also think you have a great opportunity to show off some craftsmanship with the exhaust and by using car tips it could look rushed and less refined. A nice stainless oval that follows the radius of the cutout area for the exhaust but doesn't drop too far down could be good.

If I were doing it I would come out of the can with a flange with two pipes so it doesn't look like you're making a y as well.

Title: Re: Cafe XV920R Mega-Build
Post by: MORK on Jul 31, 2017, 13:34:20
All that said - build it however the hell you want to.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jul 31, 2017, 22:45:41
 I was a little undecided about the exhaust myself. That said I always try and use parts I already have and make something out of them. I is definitely more cost effective. The pics do make things look a little off, but in reality it flows better than the pics show. Most of what you can see from the rear of the tips will not be seen because I was planning on making a fitted panel for the tail light and blinkers to fit into. Also the tips will be powder coated a dark grey or black and the frame is probably going to be red. This will make the tips appear smaller and bring the focus back to the frame. I have to at least try and bring my vision to a reality. I can always make something a little different if I don't like it in the end. The other thing that I may make is a completely different tail section so I can give the bike two different looks. 4 bolts and I can remove the whole tail section. The battery and all electronics will be mounted under the tank which would make 2 interchangeable tails possible.
As for the sound I can live with it being a little loud.
I appreciate all the interest and feedback, good to have other opinions from guys that have built some pretty cool bikes.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 09, 2019, 23:25:07
Getting Back at it. I came up with a taillight and headlight. Cut the front cowl on a plasma and welded it up. Going to used 2 projector beam lights.
Title: Re: Cafe XV920R Mega-Build
Post by: The Jimbonaut on Jan 10, 2019, 00:22:44
Holy cow, I love this so bad.
Title: Re: Cafe XV920R Mega-Build
Post by: irk miller on Jan 10, 2019, 11:12:13
The halo light looks cool. What's that out of?
Title: Re: Cafe XV920R Mega-Build
Post by: Luugo86 on Jan 10, 2019, 12:40:55
Some kickass fabrication work man!
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 11, 2019, 12:26:30
The halo light looks cool. What's that out of?
I got the halo headlight off E-bay it is a universal one that fits several sport bikes.
Title: Re: Cafe XV920R Mega-Build
Post by: Rat_ranger on Jan 12, 2019, 16:37:45
Those halo led lights are actually decent on light output.  I used one for my bike, but I removed the halo and painted the ring after turning it smooth.  They sell them to mount inplace of a bulb on more modern lights. 
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 13, 2019, 14:18:46
I found a good aftermarket top triple clamp on e-bay which made it easier to mount my bars to. As much as I liked the look of the clip-ons I will take the MX style bars and comfort any day. I used some adjustable universal bar clamps and some pro taper bars that I had. I also mounted a Koso RX-2N GP multifunction meter to the top clamp.
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 17, 2019, 23:35:13
Finally got around to the exhaust system. I am using several stock  YFZ450 and CRF450 stainless pipes as donors for my bends. I decided to run the rear pipe down through the swingarm, under the linkage, back up around the swingarm through the frame, into a Y and into the muffler. Easy enough right????  Well tacked it up and have 2 slip joints so it can al fit together.  Just need to make the front pipe so it is equal length to the rear.
Title: Re: Cafe XV920R Mega-Build
Post by: Kunphushun on Jan 19, 2019, 13:44:45
Wow, this will be a one of a kind for sure!  Nice!
Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 19, 2019, 23:44:59
Finished mocking up the exhaust, all tacked up. Front and rear are equal length should flow nicely. I added a couple of heat guards made from Yamaha YZ-F's. Just need to Tig  everything up.
Title: Re: Cafe XV920R Mega-Build
Post by: der_nanno on Jan 20, 2019, 04:45:00
Interesting exhaust - and from personal experience with XVs - yes they respond nicely to equal length headers. Talking of which, I couldn find any remark from you what the ID and OD of the tubing is?
Title: Re: Cafe XV920R Mega-Build
Post by: SF on Jan 20, 2019, 13:51:34
That stock exhaust shield has to go in place of a custom one......the ass end with the exhaust exit looks great man.


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Title: Re: Cafe XV920R Mega-Build
Post by: JAGspeed on Jan 20, 2019, 14:53:24
Interesting exhaust - and from personal experience with XVs - yes they respond nicely to equal length headers. Talking of which, I couldn find any remark from you what the ID and OD of the tubing is?
The exhaust does slightly taper out from the begining of the header to the main pipe. it is roughly 39mm OD and tapers to 42mm OD for the majority of the pipe. The muffler opening diameter is larger, can't remember the exact measurement though.