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Re: Project 920R Cafe' Build

PostPosted: Sun Feb 19, 2017 4:45 pm
Author: gs58
DGA wrote:I always look at frame loads in the front end as the forks are a lever arm trying to twist the headstock sideways. Try the stock XV and while riding at maybe 40 mph, give the bars a deliberate quick (small to start with!) turn and then feel the response as the stability of the rake and trail react and see how long it takes the bike to recover to a steady state. Mine was pretty spongy stock and raising the fork tubes up through the triple clamps eliminated most of this. But that exercise shows which way the front of the frame needs to be stiff in; the sideways twist, the front wheel and it's divergence from a straight line, which translates into head shake and in extreme cases, a tank slapper. So, the best frame design there would be with maximum section to make it resist the headstock's sideways twisting.


DGA, I think that a lot of the spongy feel that you got is due to the original puny front forks. Raising the forks through the triple clamps will reduce their length and therefore their ability to flex. Adapting stronger and shorter forks (R6 etc) will reduce flex enormously.

I really like what I see here though. It is simple, it is strong, and it is different to what we normally see. I'm watching with interest.

Re: Project 920R Cafe' Build

PostPosted: Sun Feb 19, 2017 9:14 pm
Author: DGA
Yes I said that it helped reduce flex by raising them as I did. The problem here, is that guys don't understand the load directions totally. There are some vertical loads, and the OP's frame will be incredibly strong in that direction, but that is not what makes a bike shake or wiggle. Looking from in front of the bike, the head stock will be twisted as the front wheel diverges from a straight line. Those that cut the back off their frame will feel this more as they think the stock frame to head mount will cover the lack of torsional strength, but that head mount is only pressed plate and will parallelogram, and the headstock will rotate sideways.
I hand the OP back his thread, sorry for the interruption....

Re: Project 920R Cafe' Build

PostPosted: Mon Feb 27, 2017 11:39 pm
Author: JAGspeed
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 need to add the third mount from the frame to the head. Also I was planning on adding a rear support from frame to my CNC pieces as well as one more brace up front, but I'm going to wait until I get the tank, exhaust and seat figured out before I add more frame supports just in case I need clearance for that stuff. At this point I should be able to make it a roller pretty soon.
XV frame c2.jpg

XV frame c3.jpg

XV frame c4.jpg

XV frame c.jpg

Re: Project 920R Cafe' Build

PostPosted: Tue Feb 28, 2017 12:36 am
Author: Southclaw
This thread gives me so much hope that I can also do this! I've been slowly plotting out my master plan, which includes a custom frame. But up until I saw this thread the other day I thought it could only be done by other means. Keep up the good work man!

Re: Project 920R Cafe' Build

PostPosted: Tue Feb 28, 2017 4:20 am
Author: faffi
Is that a Kawasaki KZ rear wheel I spot in the background?

Re: Project 920R Cafe' Build

PostPosted: Fri Mar 17, 2017 11:40 pm
Author: JAGspeed
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.
XV roller b.jpg

XV roller a.jpg

Re: Project 920R Cafe' Build

PostPosted: Sat Mar 18, 2017 4:13 am
Author: rantingsmith
Looks great! :GJ: Although compared to all your other trick bits the engine now looks like an antique.. :r:

Re: Project 920R Cafe' Build

PostPosted: Fri Apr 07, 2017 10:54 pm
Author: JAGspeed
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.
XV roller aa.jpg

Re: Project 920R Cafe' Build

PostPosted: Sat Apr 08, 2017 12:23 am
Author: rantingsmith
Nice choice of tank. I've been wondering about a large GS tank to increase range between fill ups for my sidecar project!

Re: Project 920R Cafe' Build

PostPosted: Fri Apr 21, 2017 10:59 pm
Author: JAGspeed
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.
XV subframe a.jpg

XV subframe b.jpg

XV subframe c.jpg

Re: Project 920R Cafe' Build

PostPosted: Sat Apr 22, 2017 2:10 am
Author: rantingsmith
:pop:

Re: Project 920R Cafe' Build

PostPosted: Fri May 12, 2017 10:35 pm
Author: JAGspeed
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.
XV seat a.jpg

XV seat b.jpg

XV seat c.jpg

Re: Project 920R Cafe' Build

PostPosted: Sat May 13, 2017 6:28 am
Author: subheatadey
You Sir are utterly bonkers :GJ:

Re: Project 920R Cafe' Build

PostPosted: Tue Jul 18, 2017 5:52 pm
Author: Tank126
Keep it up Mate!
One day I hope to have access to the equipment so i can try something like this!
Slowly building up my tools / knowledge.

Re: Project 920R Cafe' Build

PostPosted: Fri Aug 04, 2017 9:04 pm
Author: JAGspeed
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.
XV seat d.jpg

XV seat e.jpg

Re: Project 920R Cafe' Build

PostPosted: Mon Aug 07, 2017 5:15 pm
Author: JAGspeed
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 ***** 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.
XV muffler a.jpg

XV muffler e.jpg

XV muffler d.jpg

Re: Project 920R Cafe' Build

PostPosted: Tue Aug 08, 2017 4:22 pm
Author: faffi
Cool exhaust :GJ:

Re: Project 920R Cafe' Build

PostPosted: Tue Aug 08, 2017 7:20 pm
Author: Hellgate
I'll say. Good for roasting chestnuts. ;)

Sent from my SAMSUNG-SM-G900A using Tapatalk

Re: Project 920R Cafe' Build

PostPosted: Wed Aug 09, 2017 8:15 am
Author: ivogiev
Can't wait to see how you plan on routing the exhaust and what lengths for each cylinder you will use.

Re: Project 920R Cafe' Build

PostPosted: Wed Jan 16, 2019 6:42 pm
Author: JAGspeed
Getting Back at it. I came up with a taillight and headlight. Cut the front cowl on a plasma out of aluminum and welded it up. Going to used 2 projector beam lights.
XV Head light c.jpg

XV Head light b.jpg

XV Head light a.jpg

XV Head light d.jpg

XV Tail light a.jpg

XV Tail light b.jpg