Got the forks back together, 3 inches lower than stock with shaved & polished lower legs.
Also, finished the polishing of the left engine case cover.
Still have quite a bit of polishing & finish work to do.
So keep checking back here for updates.
| Got the forks back together, 3 inches lower than stock with shaved & polished lower legs. Also, finished the polishing of the left engine case cover. Still have quite a bit of polishing & finish work to do. So keep checking back here for updates. Add Comment  It has been a while since we have seen this project. The customer is now ready for us to put this thing back together. This first pic is a refresher, what we started with.  The frame is painted & ready for some new parts.  New neck bearings & some nice new billet front forks installed. This will allow us to run a disc front brake instead of the old drum set up. To finish it off there is a new 21" twisted spoke wheel with a disc. (pic below) Keep checking back here for updates on this project.   It has been awhile since we posted progress on this project but near its completion we ran into some issues. Turns out that the pinion shaft was bent which upon restart spun a bearing & smoked the oil pump. OC decided to have Harley do a complete rebuild so we pulled the engine again. Here it is back at the local Harley Dealer. Ready to be put back in.  Here it is all done. Everything is working & ready to ride! We nicked-named this the "Black & White" Project simply because we were refreshing an old Police Bike.   Lower legs all polished up. Now we just have to rebuild them & lower them 3 inches.  We also got the final sanding done on the left side engine cover. You can also see the Paulimoto modified cover, the Yamaha is gone. Now off to the polishing wheels. Keep checking back here for updates.  We got a little more sanding done on our aluminum for the XS650. Both lower legs are now ready for final sanding & polish. Even in this state they look much better than what we started with.  We also began to tackle the left engine cover. You can see the shape that it was in when we got it. Below you can see what a difference even just the first round of sanding makes. Keep checking back here for updates.   We are now at a very time consuming part of this project, aluminum prep & polishing. When removing 30 + years of pitting, corrosion & yellowed clear coat it takes a bit of time & a lot of elbow grease. This is after the first bout of chemical stripping.  We have finished the initial stage of sanding on the left lower fork leg. We removed the caliper bracket mounting points & the casting lines. You can see what it looked like before by looking at the right lower leg next to it. Still have to do the finish sanding before it will be ready for the buffing wheel.  Here is the rear wheel with newly polished lip & spoke edges. A much better look than the 30 years of grime and pitting did. The updates will be coming a little slower because of the time it takes to sand & polish but keep checking back here for updates. We will get them to the blog as soon as we can.  Finished grinding down the welds on the pipes. Since they will be wrapped there was no need to make them perfect, just had to grind them down enough to not cause bumps under the wrap.  Initially we intended to make the side covers removable but when we fabbed up the first side it did not look right. The angles between the upper & lower support under the seat were to far off for them to work. So we scrapped that idea along with the side we already made & started over. The cut out side pieces that are to be now welded on are what you see here.  We then proceeded to tack the side pieces on. You see the left side here, Later we will cut a relief in it for the carb because we wanted it to sit as tight as possible to the frame.  Here is a pic of the right side all tacked on. It has a hole cut into it for a Harley style ignition. We are making progress on this one almost daily. So keep checking back here for updates. | Dynamic BlogWe blog project progress, events & other fun stuff. Feel free to comment & check back for updates.
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