Excess Four Hundred (XS400 Brat Build)

[Rusnak_322]

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.

Sent from my iPad using DO THE TON

 

[Rusnak_322]

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.

Sent from my iPad using DO THE TON

 

[Rusnak_322]

The plan is for a flat seat with a short rear fender.

Sent from my iPad using DO THE TON

 

[Rusnak_322]

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.

Sent from my iPad using DO THE TON

 

[Rusnak_322]

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.

Sent from my iPad using DO THE TON

 

[Ant36]

Nice build I like the wooden dies for the homemade bender! Very creative!


Sent from my iPhone using DO THE TON

 

[Rusnak_322]

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.


Sent from my iPad using DO THE TON

 

[canyoncarver]

Nice bender. Well done.

 

[Rusnak_322]

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.

Sent from my iPhone using DO THE TON

 

[Rusnak_322]

Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

Sent from my iPhone using DO THE TON

 

[Rusnak_322]

Also - picked up some tires.

Sent from my iPhone using DO THE TON

 

[irk miller]

Loving the ingenuity, my man.

 

[Rusnak_322]

Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

Sent from my iPhone using DO THE TON

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.




Sent from my iPhone using DO THE TON

 

[irk miller]

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.

 

[Rusnak_322]

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.


Sent from my iPad using DO THE TON

 

[irk miller]

That's what a deck of cards is for

 

[Rusnak_322]

I made the slugs and tacked it in place. It came out near perfect. I am glad I tried this vs paying someone to do it.

I used a metal stake that is made for concrete forms as the base for the slugs. The frame and hoop are the same OD but different walls, so I spent some time with the angle grinder to make them fit.

Sent from my iPhone using DO THE TON

 

[Rusnak_322]

Got some work done, mounted the fender in place, got in a rear brake master and getting ready to recess the rear brake light into place. Also mocked up how it is going to look with the tires.

Sent from my iPhone using DO THE TON

 

[OneOffStroker]

Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

I don't know if you have thoroughly made up your mind about painting the wheels or not, but I can tell you that you can leave the rubber in the wheels and have them powdercoated. I powdercoat and sometimes I get parts that can't have the bushings removed, and I've never had an issue with leaving them in.

I like the inspiration pic at the beginning of the thread. It's very similar to what I have in my head for my wife's CB650.

 

[Rusnak_322]

I don't know, I read a few posts on either xs400.com or the Facebook page about people ruining the wheel. Some did OK, but I can paint them for 1/2 of the cost for powder. I was quoted $125 per rim. I bet I can buy all the paint (primer, base & clear) for that amount.


Sent from my iPhone using DO THE TON