Sporty Tank

In my attempt to contain spending on my project I have been scouring a certain auction site for a suitable fuel tank. I knew it had to be a sportster style tank and, once I'd looked over a few pictures of XS650 frames I knew it needed to sit lower rather than higher on the frame's backbone. Because my frame is not receiving any major stretch in length I want to avoid making it appear even shorter by mounting the tank too high or fitting high rise handlebars. I'm hoping a low slung tank and some drag or similar handlebars will help create the illusion I'm after. For several months I placed bids on numerous suitable tanks only to lose out to other buyers with more money to spend. A couple of days after once again missing out on a good looking tank to a higher bid I received an e-mail from the seller offering me the chance to buy his Sportster tank at my highest bid. I duly paid the man and very quickly received a very good example of an original Harley Sporster tank.

I was really pleased with the condition of the tank, there were a few minor rust patches along the lower edges where all fuel tanks are most likely to suffer chips and dings but overall it was very good. No visible dents and even the screw in cap was in good condition.

Whilst waiting for the work to be carried out on my frame I decided to use the time to strip the tank and prepare it for fresh paint. Visiting one of the large diy stores I sought out the cans of paint stripper. Instinctively, I initially focused on the familiar green tin of Nitromoors but, in my continuing effort to save cash, I decided to buy the stores own brand of paint stripper. It was twenty percent cheaper and promised to do all that the leading brand would do. I would soon regret trying to save a couple of pounds. Despite sanding the tank prior to applying the paint stripper and layering on two generous coats of the white gloop as per the instructions it had no effect whatsoever on the paintwork. I knew I was in trouble when I managed to drip some of the stripper onto my hand without realising I had. With Nitrommoors you get a strong stinging sensation as the solvent burns your flesh, this brand had no such effect.

Another trip to the shop and I was brushing a layer of clear Nitromorrs that soon had the top layer of paint crinkling up in blisters. I take my hat off to Harley Davidson, they certainly know how to apply paint. It took me two whole tins of stripper to remove the thick coating of paint and lacquer that had protected the tank so well. After much sanding and having treated any rust patches with a neutraliser I gave the Sportster tank a coat of grey primer.

In The Hands Of Sooty!

I loaded the car with the frame, swing arm, rear wheel, rear shocks and associated axles, spacers etc and made the forty five minute journey over to Sooties workshop. On my arrival the man in charge of turning my ideas into metal reality popped his head around the door to his shop and smiled. After accepting and consuming the offered cup of coffee it was time to empty the boot of my car into Sooties workshop. We discussed what I wanted once more and marked up areas of frame that would need to be removed and or modified with a permanent marker pen. 
Now all I have to do is wait a few weeks while the alterations are carried out and I get the call to collect my stretched and lowered chassis parts. I have a long list of jobs I can be getting on with while I wait including, stripping and primer painting the Sportster tank I intend to use, buying and installing XS650 taper bearings onto a set of  Suzuki Bandit 600 yokes in the belief that this will allow to front end and frame to work together in harmony and the XS engine needs a good going over with de-greaser before I think about heaving it into the frame.
For the first build up I'm not concerned with making parts pretty; just making them function efficiently and safely. My intention is to put a few hundred miles on the bike in its rough state before committing to paint and powder coating. No point ruining fresh paint when you find a bracket needs re-locating or you need to wield the grinder to gain another sliver of clearance between two moving parts.

The standard fuel tank mounts by way of two circular rubber fittings that slide into two curved metal cups that are spot welded to the neck gusset as shown in the photo below.

I intend to use a Sportster tank that I have acquired and the front mounting brackets line up exactly where the steel cups are positioned. Using adjustable grips, a large wrench and hammer and chisel I carefully worked my way around the offending metal until, albeit in several pieces, each cup was prised free of the frame.  Left behind was the ugly remains of the spot welds and small lumps of attached metal.

At first I used a file to reduce the blobs of weld but because of the surrounding framework it proved impossible to keep the file flat against the neck gusset. I was forced to use an angle grinder to take off the remaining steel. I'm not concerned about getting a perfect finish as yet because the area being worked will need to be drilled through and a metal tube welded inside the gusset to provide a strong mount for the Sportster tank. I'll worry about making it pretty after all the modifications have been completed.  I sprayed on a  generous coat of primer to keep the dreaded rust at bay. The next time I do any work to the frame should be after Mr Sooty has completed the frame rail and swing arm modifications.



Frame alterations

I visited Sooty's Customs workshop yesterday.
When I finally found the small cluster of unmarked farm buildings I was directed towards an inconspicuous green door by a chap who appeared to be restoring furniture. I knocked on the door and it was opened by the man himself, Sooty. With a broad smile and a friendly handshake I was welcomed into the workshop. All about the building dozens of bikes sat in various stages of build or repair and the delicious smell of oil and grease made an old biker feel right at home.

As Yamaha intended.

In order to achieve the look and riding position I'm after the XS650 swing arm needs extending by approximately two inches, the upper frame rails that would normaly support the seat require lowering and the rear shock mounts will have to be re-positioned. I explained this to the bearded Sooty and showed him a photograph of the look I was searching for. With a confident smile he said he could do what I required and quoted me a very fair price for the amount of work involved. Over a cup of coffee we talked further about my idea and the various components I wished to marry together. I am due to deliver all the neccessary parts to Sooty's workshop next weekend so he turn my ideas into metal reality. Like a small child I'm finding difficult to be patient.

In the beggining

After over a year of searching I have finally assembled enough parts to start the long process of building a custom bike from the ground up. With no real budget to buy parts it has proved difficult and often frustrating trying to aquire components at affordable prices.  But hey, that's life so I'll stop moaning and get on with this.
I have wanted to build another chop for many years now but life and all its many interuptions has always got in my way. More to the point, I have allowed life to get in the way of my building another bike, so, at the ripe old age of fifty one, I decided that time was running out if I was to build and then enjoy riding a custom bike so I'd better get on with it.
Over the coming months I intend to describe the process of taking the collection of motorcycle parts I've accumulated and transforming them into a fun to ride chop that is at home on the road not parked up and polished in a warm, dry garage. I'm not a fan of over the top show bikes, I prefer understated, practical machines that are designed to look good whilst being ridden hard rather than a piece of exagerated art that quivers in fright at the thought of being hustled through the twisties or trudging home through a downpour on a rain soaked night.
Never having blogged before it's probably going to prove just as challenging updating these pages as it is building the bike but I'll give it my best shot.