XR400 Cafe Inspired Project

grcamna5 said:
Beautiful custom Honda single,I've always loved all the strong Honda small singles too. 8) I'm installing a modded XR200R motor in my 81' CB125S w/ Rebel 250 front end presently.
I'm subscribed ;)

Im a huge fan of the small bore air cooled Hondas. Its fun to try to make them go fast.

Although its off the original topic, I build these with (highly modded) XR100s...












Your XR200 project sounds sweet!
 
I gotta say you have done some beautiful work. Your fab skills are obviously very good and what you have done so far looks beautiful. I have to say, though, your frame has a glaring weakness from the head stock to the lower engine cradle, and down the back bone. It looks like you have the potential for major lateral flex (almost a lateral hinge where the single tubes split into two at the rear of the engine and in front of the engine. The original XR frame uses a much larger cross sectional frame members there and they are much more reinforced. As originally intended it was they are adequate (in the dirt), but in this case, with a street (sporting) purpose, there would be much more lateral forces induced into the steering stem. The frame should triangulate from the stem to the rear of the main frame to try to keep the swing arm pivot and the steering head in line, and the upper shock mount should be in as direct a line as possible with the back bone.

This may never be an issue, if the intended purpose is a bar hopper, "art piece", or a cafe racer themed chopper. But considering the quality of the work you are putting forth, it just seems that purpose would be selling your self short.

Please don't take these comments as berating, or bashing. They are not intended to be as critical as they probably sound. I really do like what you are doing on this bike. They are just the musings of a mechanical engineer.
 
settintrendz,
What brand exhaust/headpipe do you have on the custom XR100 you just posted pics of?
I want to have a 1.5" dia. custom headpipe made for my CB125S/XR200 to match the stock down pipe of the 81' CB125S;do you know someone not far from Pittsburgh,PA. who would make one for me ?
 
Thanks you for the input 8ball. I don't take any comments, criticism, etc as being mean or harsh. My skin is plenty thick and although I have many years of experience and education in chassis design and fabrication, I do not, by any means, think that I have nothing left to learn. Ive always felt that an open mind, not closed by pride, allows for natural continued education. I really do appreciate and welcome all of your thoughts and suggestions.
All that said, you are 100% correct. But, I am not finished with the chassis. There are four critical points on the main frame that still need attention-by-triangulation. In fact, the parts are made, just haven't put them in yet. Ill get there shortly.
 
grcamna5 said:
settintrendz,
What brand exhaust/headpipe do you have on the custom XR100 you just posted pics of?
I want to have a 1.5" dia. custom headpipe made for my CB125S/XR200 to match the stock down pipe of the 81' CB125S;do you know someone not far from Pittsburgh,PA. who would make one for me ?

The muffler is a ProCircuit unit. The head/mid pipe is one of our parts we make for these conversions (CR85chassis, XR100 motor).

Im sure that there are many locally that can do it, but Im sorry to say that I don't know anyone in your neck of the woods for the job.
 
settintrendz said:
Thanks you for the input 8ball. I don't take any comments, criticism, etc as being mean or harsh. My skin is plenty thick and although I have many years of experience and education in chassis design and fabrication, I do not, by any means, think that I have nothing left to learn. Ive always felt that an open mind, not closed by pride, allows for natural continued education. I really do appreciate and welcome all of your thoughts and suggestions.
All that said, you are 100% correct. But, I am not finished with the chassis. There are four critical points on the main frame that still need attention-by-triangulation. In fact, the parts are made, just haven't put them in yet. Ill get there shortly.

Cool. I am following this build with great interest.
 
Well, I need to put the wheels together so I can get it sitting on its own weight, get some scale/ perspective and dial in where I want controls.

I ordered the Excels in silver. My plan was to do the hubs black. But at the last minute I decided to anodize the hubs red and powdercoat the rims black, instead of silver. Im waiting on the rims from the coater, but here are the hubs, back from anodize, and after I machined all the thru-holes raw...





New stainless spokes and nipples



I should be able to lace up the wheels and mount tires by the weekend
 
8ball said:
I gotta say you have done some beautiful work. Your fab skills are obviously very good and what you have done so far looks beautiful. I have to say, though, your frame has a glaring weakness from the head stock to the lower engine cradle, and down the back bone. It looks like you have the potential for major lateral flex (almost a lateral hinge where the single tubes split into two at the rear of the engine and in front of the engine. The original XR frame uses a much larger cross sectional frame members there and they are much more reinforced. As originally intended it was they are adequate (in the dirt), but in this case, with a street (sporting) purpose, there would be much more lateral forces induced into the steering stem. The frame should triangulate from the stem to the rear of the main frame to try to keep the swing arm pivot and the steering head in line, and the upper shock mount should be in as direct a line as possible with the back bone.

This may never be an issue, if the intended purpose is a bar hopper, "art piece", or a cafe racer themed chopper. But considering the quality of the work you are putting forth, it just seems that purpose would be selling your self short.

Please don't take these comments as berating, or bashing. They are not intended to be as critical as they probably sound. I really do like what you are doing on this bike. They are just the musings of a mechanical engineer.
my thoughts exactly the tubes being all curvy and such small diameter,it is contrary to proper frame design
 
Very cool. I'm in for the ride and I'm excited to learn a few things along the way.
 
Man! XB... I have to apologize. I really hope I'm not keeping you up at night thinking about all these critical mistakes I'm making. Hahaha
 
settintrendz said:
Man! XB... I have to apologize. I really hope I'm not keeping you up at night thinking about all these critical mistakes I'm making. Hahaha

Best. Thing. Ever.
 
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