Sandrew's XS400 - v2.0

Sandrew

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Re: Sandrew's XS400



"The fuse box"


Rearsets' brackets.



Tank's mount didn't quite suit the style anymore.


Actually there were other reasons, too. First of all, it was ugly and I didn't need those relay mounts in there and second of all, I wanted to raise the tank a "bit".



Added a few more layers of fiber glass inside the cowl to stiffen it up, would have been perfect for track use but in the streets I wanted it to be strong. Weight doubled but I can live with that.




Then cleaned up all the welds and took the frame along with some other bits to powder coating (finally held on to schedule).

Uuuh, 30 hrs of work into frame but well worth it.


Sander
 

Sandrew

New Member
DTT BOTM WINNER
Re: Sandrew's XS400

...

In the meantime.
All the paint off the tank. Now it'll see some epoxy primer and then filling as there are quite a lot of small dents.


Happy times!



And the bearing cones and VIN plate back on.


Nice, my whole garage is white from the dust...

It took some time to get cowl's bottom edges to line up with frame.


And it's final position. (Oops, haven't shown you how the tank sits with the new mount. Tanks bottom end is parallel with subframe rails, just the way I like it.)


You can see the difference in this photo.


Then with angle grinder's help I got it almost smooth.


And just finished with fiber glass filler at midnight (2.5 hours and 7 times filling/sanding).


Cowl and tanks is off to epoxy primer tomorrow. My painter said he's doing the final filling himself and makes them ready for paint, which means it's time to think about COLORS!

Any ideas? Because I have too many of them..


Sander
 

Nojokirk 75cl360

DT250 project in the works!
Re: Sandrew's XS400

dude, this has to be one of the best xs 400 builds i have seen, im really diggin on it!. im posted for this bugger
 

two-smoker

I reject your reality, and substitute my own!
Re: Sandrew's XS400

Having the tank in the original position gives the whole bike a "chunkier" look. Your new position slims it down visually. Quite a difference in appearance for such a small modification.
 

Sandrew

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Re: Sandrew's XS400

Yeah, talkin about the color. I could really use your help here. The variety is too big, need to narrow it down! It's only matter of days to get the bastard painted.
Ou and got the new piston rings, too. Just had the pistons machined a bit to fit them today. Plan is to, get the engine in tomorrow and then wiring and then and then and then... I can see the light.
 

Sandrew

New Member
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Re: Sandrew's XS400

Pistons after machining and before cleaning.


And top end done.


In ze frame. Used the easy technique, laying the frame over the engine not the opposite.


Also installed lower tree and stem bearings.


Hopefully get new swing arm bushings and pivot in a few days so I could get it rolling again and move onto electrics.

Got the tank and cowl back from painter. These now have thick layer of epoxy and primer.


I ran out of paper and it's Sunday, so not much of a progress.


--------

About the swing arm.

New bushings are in.


It's good to have acquaintances with great expertise as I found out modern plastic are way better than bronze.


Also bought new battery, fuse box and some LED's I am not yet spreading word about.

(I should get a real camera for once.)

So It was about time to get her on her feet for good.

It's one way to put on a rear wheel.


Threw in all the electrics to see, what I have to work with. Not much to do actually

Ought to finish wiring by weekend.

At the very moment.


Aah, it brings back some memories, the final tuning and assembly just can't go smoothly. In every step there are some drawbacks, but I think I can manage.

----------

Finished wiring the rear section, everything fits under the cowl nicely. Only thing left to do is starter, I ran out of wires.











My upholsterer wanted me to make a rough seat rendering, so there it is.


As usually, more to come.

Sander
 

Sandrew

New Member
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Re: Sandrew's XS400

Front end.

Argh, paid twice the price for ears than headlight itself cost and still needed to spend some quality time with 'em. First of all, The angle needed changing and then twisting to get them lined up with bucket mounts.

After bending befor twisting.


To get them sit correctly i needed to use them inside out, which meant the ugly and unfinished chromed sides were left revealed. No prob a bit sanding to get all the chrome and copper of the rough sides and polish. Actually makes no difference if polished or chromed.

(bracket is polished fork mount chromed)


And yet another modification as the inner side of the rubber tubes were 2mm wider than fork. Used 1mm plastic to cover that space.


And in use.


Cables cleaned, lubricated and siliconed + ends polished.


Bars and controls on. Master cylinder needed a bit modifying as the bars are quite short, there were some complications but more on that later.



Tunnel for throttle cable.




And a teaser before seat goes into making and tank/cowl into painting.


-------

New spring and side stand installed.


Converted my new headlight to H4.





And it's about to get real comfy.


Sander
 

Sandrew

New Member
DTT BOTM WINNER
Re: Sandrew's XS400





Made some changes under the cowl, flipped the battery, secured it, and did better mounting for solenoid



All the wires pass through nicely.


Why the ignition switch has to sit that high like a schlong?


But some viagra well help it calm down.


Now we're talking, i like symmetric, everything is in the same level.



Seals arrived.


Next in line was the seat. To keep the price low I told the upholsterer not to spend too much time on the underside. It was my turn now.
Before: (actually I had already placed first rivet)


And after 35 rivets, some cutting/cluing and shortened bolts.


Everything organized underneath the seat.



Now I'm excited..





Sander .
 

two-smoker

I reject your reality, and substitute my own!
Re: Sandrew's XS400

Your build makes me wish I had a 400 instead of a 500...
 
M

misteroddjob

Guest
Re: Sandrew's XS400

Great build on a bike I owned years ago.
I like the details that you thought about like this one:

I'm going to steal it for my build.
Looking forward to seeing the final product.
 

Sandrew

New Member
DTT BOTM WINNER
Re: Sandrew's XS400

Made meself a little gadget which comes handy when not working on bike. 8)



Actually I should have wrote: "First Do The Ton, then.."

Sander .
 

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