'80 XS400 whiteout

Yep, integrated signals.

I also ordered some new RFY shocks since the ones on it were worn and the rods all rusted.

Rims powder coated and laced up. The red looks much more pink in the pictures.






Frame gussets and most of the electronics pan done. Going to add some small gussets to the rear tubes.







I also had to bend the rear hoop up more to get more clearance between the tire and the taillight.

 

Welded up the mufflers, will be painting and then wrapping them later. Also, got most of the electronics and battery mounted. Will be moving on to the harness today.

Excuse the leftovers of my oven and filing cabinet powder coat oven laying against the house, have to get rid of that still.

 

the reg and rectifier are going on the outside on the bottom so they'll have lots. I'm thinking of making some louver type deals on the bottom.

 

I have some foam tape on the battery already so it is spaced off the bottom and will also be spaced off from the seat as well with the foam.

I'm trying to keep it open to keep air flowing in to it but also want to keep the water out.

 

Cut out a section of the bottom of the tray, then cut out some of the louvered section from the stove i dismantled for my PC oven and tacked it in. This should help promote airflow in there like you guys mention. I also cut a hole near the front and added a grommet to bring the wires from the engine in. too many big ones to hide in the frame tubing so that will have to do.







I welded some tabs to the frame and made up a plate to hold the reg and rec. Tucked under the engine and just above the bottom of the frame rails so it should get lots of air and still be somewhat protected. Still have access to all the drains and sump, doesnt cover much of the bottom of the engine and it comes off in a minute with 2 bolts. Best part is you'll never see any part of it with the exhaust and filter cover on.





Exhaust mounts welded up.

 

Made a seat pan.




Then bought a meter of vinyl and some foam and made the cushion and covered it.





Made the plate mount, not sure if I like it or not but has no where else to go.




Adding some spools and finish welding tomorrow then I can paint and start to assemble.

 

Hahah, she definitely does appreciate it. All of the customers at her work keep asking when it's going to be done so she must talk about it often.

Cleaned up the frame yesterday so I'm hoping to get some paint on it today depending on weather.

 

I've never done any welding or metal working before really either. I was borrowing a welder when my wife bought me a cheapy one to toy with. Bought a set of used torches to bend tubing and a cheap angle grinder from HF. Definitely no fancy machinery here. I'm learning as I go.

 

Getting close!!! I replaced the swingarm bushings but notice that the swingarm has quite a bit of side to side play. I don't know if this play was there before or not. I checked a diagram and it lists a shim (PN 240-22127-00-00) between the bushing and the dust seal. I don't seem to have those. I google the part number and it comes up with many different things. Anyone have a picture of these shims?

 

Haha, it's clean for now, going to be hard to keep it that way.

Thought I'd show how I added spools for anyone else interested.

Drilled a 1/2" hole, filed a little of the points off a nut with an integrated washer and hammered it in for a tight fit, then welded the washer part that stuck out the back of the arm.