I think I shall call you BRICK.

[Bajanate]

Hi Guys,
New to the forum as a member but I've been poking around for a few months...lurking.

I just picked up a 1982 XS400 Special Heritage (black) and then got lucky and also grabbed a 1981 XS400 Special (burgundy). All within a couple weeks of each other. Needless to say, I will have some parts for sale at the end of the build

So the first one was half torn apart when I bought it. The frame was on it's way to becoming a hardtail and was tacked back together to make a rolling chassis. I have since completely torn it apart and currently resides in a number of boxes. It will be a parts donor with it's engine as a spare and some of the black hardware. Namely the headlight assembly, forks, and other odds and sods that will keep me from going to the wreckers every other day. Although I noticed they do have one XS in the back corner...hmmmm.

Day One. Today.
I wanted to go for a more classic cafe look and so of course required a different tank. I ended up with an XS500 tank. It's a biggun'. But with only slight mods to the frame (cutting off the coil mounts) and a little hammering in the tunnel of the tank...she fits like a glove! (pics will be up soon) I think there will be some handlebar dents coming yet. The tank is quite wide and the bars hit it at full turn.

I will rebuild the black set of carbs and install pod filters. the rear brake and shifter will need small modifications to make them more accessible as well. Controls are going to need some work. The '81 has definitely seen some moisture and has been subjected to some rather nefarious bubblegum and paperclip repairs.

The rear frame will also receive some touches with joining it again after cutting. Also a seat pan, brake and turn signals, new rubber font and rear, exhaust tape, and also all the regular maintenance stuff.

But after day one on this build, it's starting to take shape.

I will post pics soon of my newly purchased parts washer with the Hamilton Beach indoor/outdoor grill heater I modded to heat the fluid in the tub and extra filtration unit... Works Like a charm!!

Cheers,
Bajanate

 

[Bajanate]

I haven't made any updates recently although some work has been done. With flooding here in Calgary, things have slowed down a little bit. Although Princess Auto is currently open 24/7! Which has come in handy for a few late nite sessions in the garage.

 

[willem]

looks like a nice project

Both bikes look nice actually. Those bars are low! no wonder it's hitting the tank haha

welcome to the forum !

 

[Bajanate]

OK... many pics to come soon. One bike build became a two bike build. Still went for the cafe on one. The other now has a monoshock rigged up. Post some pics tonite if all goes well.

 

[Bajanate]

So two very different versions of the same bike...

The burgundy '81 Special became the cafe racer instead of the parts bike. The '82 Heritage Special became a bobber of sorts after all. Although very different from the hardtail it was too become.

The bobber's engine was rebuilt bottom to top. The cafe's engine was ok but needed some of the other stuff rebuilt. Caliper, master cylinder are done and carbs this week hopefully. Frame mods on both took awhile to get right. I also added an inch if tubing to the center of the bars too widen them a touch. They don't bang the Tank now.

My uncle is building the bobber and the monoshock is a little more involved to build. My cafe had the rear changed twice. First draft was not so good. They should go to sandblasting any time now. Cafe has an XS500 tank and I'm building a custom seat. The bobber is all custom so stay tuned.

I'm a little behind schedule as I'm a single dad of three. Looks like I may have to wait till after winter now to ride. But I'm enjoying the process of building as much as anticipating the riding. Thinking about other projects now that I've got my feet wet. Also more pics if anyone is interested.

 

[willem]

I like where this is heading

 

[xschris]

Good start to it

 

[dan821821]

Im not big into the cafe racer look but ill be watching the goings on with the bobber. for some reason I love the monoshock look.

 

[Liamthedevastator]

Holy moly, loving both of those chassis! And the engine in the cafe... it's like porn (speaking as someone with their engine in pieces (what have I become??))

 

[Bajanate]

Some more pics...moved the coil mounts to the front of the frame underneath the tank.

 

[Bajanate]

Made a heated parts washer using a Hamilton-Beach grill...and some extra filtration. Using a water based cleaning solution so as not to blow it up! Bubbles the paint on the parts washer but works extremely well.

Also made up a very large tub of molasses and water for removing rust. Worked extremely well. Mixed up about 15 gallons of water with molasses at about 9 parts water to molasses. Started throwing parts in and the old XS500 tank (which was very rusted) at the beginning of tear-down. In a couple weeks about 99% of the rust was gone if not all of it. Super cheap.

 

[Liamthedevastator]

Molasses and water??? Now i've heard it all. Great job on the parts cleaner, that's an A+ heating mod

 

[willem]

that's one hell of a cleaner...

wish I had one of those.. and a garage to put it in lol

 

[Scorpio1963]

water with molasses partial ingredients to my fish brine for smoking

 

[Bajanate]

The molasses creates a chelating process that breaks down the rust and gently removes the surrounding paint as well. No pitting and does not affect any rubber grommets or the like. Simply rinse with water and or alcohol afterwards.

 

[frwinks]

brilliant

 

[Lou Ranger]

Has anybody tried chelating their carbs?
If it doesn't damage the rubbers, could it be a sure (but slow) way to do the perfect cleaning job?

 

[xschris]

Cool tank

 

[Bajanate]

Re-assembly has begun!!
Triple tree's went on today and tonight I will be touching up other bits of the front end. The tank is almost ready for paint. It had a few leaks that needed repairing and a skiff of body filler to straighten it out. The headlight assembly is ready for paint but I need a warmer environment to do so.
Frame is back from sandblasting and has been painted. I used gloss black engine paint and then a coat of roll bar/chassis paint. Hardens properly in a couple days and will work well hopefully. Both paints are high temperature resistant. I bought the chassis paint at Auto Value and the engine paint at Canadian Tire.

 

[Bajanate]

OK. So this is where I'm at on the cafe build. I'm trying to keep it on the cheap as much as possible. New controls and switches and such are tempting as I rove the internet but as far as I know, everything still works on this bike. So cleaning parts as I re-assemble is the order. I will have to replace a few parts like the clutch cable and get a shorter front brake hose. I will also build LED's into the seat design for tail lights and blinkers.

Wrapping my head around the wiring is the chore right now. It will be kick-only and as simple wiring as possible. Seems to be what everyone is doing and it makes sense. Plus less space to hide things now. Probably build a harness mostly from scratch. This one is the '81 XS400 Special II. Any recommendations on which diagram to use? Battery for starting, all lights on a kill switch for starting...