Hi there & pics of my recently completed project.

user10645

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Hi all, been using the site for advice since picking up a 1982 XS400SE (4G5) last September as a winter project. Though you might be interested in seeing the result. Not sure how to descibe it - Brat Tracker ?
I have uploaded before, during & after pics in my public albums so all should be viewable.
The donor bike has 41,000 registered miles but a PO has swapped out the engine (for another 4G5) so no idea of it's mileage - however 150psi both sides dry so no worries on mechanicals - just had to sort out with DVLA (UK)!
Basic rundown on work carried out;
All balls taper bearings in steering stem, needle rollers in swing arm and all wheel bearings.
New sprocket dampers, sprockets & chain.
RFY aftermarket rear shocks.
Hurricane European bars and after market shorty levers.
Domino throttle & grips.
All cables renewed.
Carbs cleaned & new diaphragms fitted. 140 Main, 42.5 pilot, 150 main air & needle on 3rd groove - little lean - still work in progress. Petcock refurbed.
Motad 2 into 1 exhaust & pod filters (taped 80% at present).
Stripped spark plug thread (LHS) repaired with helicoil insert.
Sheared exhaust stud drilled out & re-tapped.
Worn gear selector shaft replaced
New gear & kick-start levers
Lots of parts media-blasted & powder coated (see pics)
Tail hoop fitted, original fenders shortened & re-used
New metal seat pan fabricated, fitted with FZS600 latch, foamed and covered.
Tank, fenders & headlight shell blasted & powdercoated for corrosion protection then prepped, sprayed and clearcoated for finish with new TZR decals
New Avon Roadrunner boots!

I think that's about it !! Now I need some decent weather for riding.

All / any comments welcome (and yes I have fitted an in-line fuel filter since taking the photos - cheers!)
 

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I'm curious about the shocks as well:)

Beautiful job mate, great looking bike before and after. I like your frame colour choice, looks really sharp. What paint did you use on the engine? That also looks very nice, great finish. Congrats!
 
The paint on the engine casings was powdercoat titanium. The crankcase was just a standard aluminium VHT a end the cylinders are bare aluminium (just cleaned).

The RFY shocks are a reasonable replacement for stock. I'm not into performance (got the other bikes for that) more just the esthetic. Couldn't justify the expense for Ohlins or Hagon for a 400cc bike so these suit just fine. There are various websites that give info on re-build & improvement for these shocks but I don't have any complaints with them out of the box to be honest.
 
Thanks for all the positive comments guys. The tail hoop was made by this chap paul@oneoffwe.co.uk, he advertises on ebay uk (oneoffweldingandengineering), so he made one up to the dimensions I gave him. Fit perfectly with slugs provided and he has the template. £40 from memory. I re-used the rear support to take the seat latch after cutting off the fender brackets and re positioning them on the lower part of the hoop to suit the shortened rear fender.

The seat was a labour of love! Couldn't find a seat to fit direct so decided to have a go at fabricating my own. Kept the front attachments on the frame and made a pan from some 1.6mm sheet that I had. Used the stock front attachment brackets and fitted FZS1000 rubbers from yambits to suit frame (4 of them). Made up a latch striker plate from some 4mm plate and was ready for foam & cover. Used closed cell foam from ebay - shaped with saw/grinder & surform rasp in that order, then some of the original seat foam for butt-kindliness (is that a word ?). Cover is marine grade vinyl that I stitched on my wife's sewing machine with the appropriate needle and bonded polyester thread (I really wanted the red stitching to fit my colour scheme). Used a product called spike-strip to attach the vinyl - great stuff just pop-rivets to the pan-once again ebay to the rescue! Turned out great in the end took about a week and cost about £80 all in.
 
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