Author Topic: My XBR project  (Read 2477 times)

iansoady

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Re: My XBR project
« Reply #90 on: November 25, 2022, 02:46:58 PM »
One step forward....

I've just tested the tank with petrol and there's a very slight weep from one of the new welds. They did say to bring it back if any problems.....

Just as well I tested it.
Ian.
1952 Norton ES2
1986 Honda XBR500

Moto63

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Re: My XBR project
« Reply #91 on: November 25, 2022, 02:55:01 PM »
Shame Ian, things were going so well too. Just make sure you empty it first before taking it back  😉💥🔥.

Ian

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Re: My XBR project
« Reply #92 on: November 25, 2022, 03:01:52 PM »
Hi Ian I have just re read this thread from 1st entry. You are doing a fantastic job and I now feel totally incompetent in the world of motorcycle restoration/modification. Keep up the good work and I know you will be pleased with the end result.
PS I actually liked it in original guise but I know you had the bit between your teeth from the word go to alter it
One of the other Ians
1 SRX 1 C400X

iansoady

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Re: My XBR project
« Reply #93 on: November 25, 2022, 04:14:32 PM »
Thanks other Ian.

To be honest none of what I've done so far has been particularly technical or needed special equipment. I do tend to spend a long time just sitting looking at it to decide what I want to do and how to do it although quite often I get half way through something then think of a better solution! Or, as in the case of the side panels, one presents itself. I'm determined not to alter anything original so it can always be easily reverted to standard as and when.

One thing that helps is having a lathe - I've bought a Monza type petrol cap and need to turn an adaptor to fit it onto the filler neck. Diligent internet search has turned up a fairly local company to me (Warwick) who provide a huge range of resins and talking to their technical people they've suggested this one to stick the adaptor in the tank neck. https://www.alchemie.com/epoxy-resin/ep575.html It's about £20 for enough to do dozens of tanks......
Ian.
1952 Norton ES2
1986 Honda XBR500

mthee

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Re: My XBR project
« Reply #94 on: November 25, 2022, 06:37:06 PM »
Good score on the side panels!
Fear of the unknown does not mean the unknown needs to be feared

iansoady

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Re: My XBR project
« Reply #95 on: November 26, 2022, 10:06:04 AM »
I think as I'm going to modify the side panels that I won't need to raise the back end of the tank as I can contour the panels to fit snugly. We'll see when they arrive. I'm also optimistic that the special glue I'm getting will be useful to stick aluminium infill extensions to the panels.

I was just thinking that despite the kind words people have offered, the mods I'm making are not that radical and nothing compared to some projects here - the blown XBR by Joolz to name but one. I stand in awe of that!
Ian.
1952 Norton ES2
1986 Honda XBR500

Itsme

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Re: My XBR project
« Reply #96 on: November 26, 2022, 02:22:30 PM »
Hi Ian

I take your point about some of the excellent projects done here and certainly there are people out there whose skills leave me speechless. However for me what has captivated me about this thread is its very ordinariness, you are not using superpowers to craft an unattainable goal, quite the opposite you are crafting something that given the time and money I could think of having a go at myself.

For me this is a good feeling, it encourages me to look at what I can do rather than stand in awe of what I can't do. I really admire people with skills I haven't got, as my comments about welding showed, but I also like to be part of a group of like minded people I can relate to.

One of the many Ians

iansoady

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Re: My XBR project
« Reply #97 on: November 28, 2022, 03:49:16 PM »
Just had the welds on the tank redone so will test tomorrow - hopefully OK now. Collected some sheet aluminium for making revised side panel mounts and a chunk of 2.5" diameter aluminium to make an adaptor for the Monza fuel cap I've bought.

A cheap petrol tap from ebay has arrived in the post and I've left its rubber seal in a jar of petrol to check that it's E5/10 proof. It seems quite a well made thing and for less than a tenner delivered what's not to like? https://www.ebay.co.uk/itm/314223108267

A bit chilly for garage work today though.
Ian.
1952 Norton ES2
1986 Honda XBR500

iansoady

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Re: My XBR project
« Reply #98 on: November 29, 2022, 11:32:45 AM »
The tap seal seems to have survived 24 hours in a jamjar of petrol without any visible effect so think it's safe. I'll leave it for a bit longer just to be sure.

Welding seems to now be petrol proof. I've made a fairly rich petroil mixture and swished it around inside in the hope that the oil will help to control any internal rust. A small amount of powdery stuff came out with the petrol so it would probably be sensible to include a filter in the fuel line.

Faced off the chunk of 2.5" aluminium for the petrol cap adaptor ready to produce vast amounts of swarf.
Ian.
1952 Norton ES2
1986 Honda XBR500

Moto63

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Re: My XBR project
« Reply #99 on: November 29, 2022, 01:16:30 PM »
Good news with the weld holding up this tie round Ian. 👍
Cheers, Michael

JOOLZ

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Re: My XBR project
« Reply #100 on: November 30, 2022, 10:49:09 AM »
Thanks other Ian.

To be honest none of what I've done so far has been particularly technical or needed special equipment. I do tend to spend a long time just sitting looking at it to decide what I want to do and how to do it although quite often I get half way through something then think of a better solution! Or, as in the case of the side panels, one presents itself. I'm determined not to alter anything original so it can always be easily reverted to standard as and when.

One thing that helps is having a lathe - I've bought a Monza type petrol cap and need to turn an adaptor to fit it onto the filler neck. Diligent internet search has turned up a fairly local company to me (Warwick) who provide a huge range of resins and talking to their technical people they've suggested this one to stick the adaptor in the tank neck. https://www.alchemie.com/epoxy-resin/ep575.html It's about £20 for enough to do dozens of tanks......
Looks interesting, I used JB weld to attach the filler neck to the tank, its still holding out after 6+ years of use

iansoady

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Re: My XBR project
« Reply #101 on: November 30, 2022, 12:23:13 PM »
I did a mini test of JB weld using my faithful jamjar full of petrol. I carefully joined 2 bits of mild steel taking care that the faces were clean and roughened, and then clamped and left for 24 hours before dunking in the petrol. The first week looked OK and the bond was still strong - couldn't break it by applying a lot of force - but after another week or so the surplus JB weld could be peeled off with a fingernail and when I put one component in the vice and twisted the other with pliers the joint failed.

Admittedly that was quite a harsh test as the joint was submerged. It would probably be fine if only exposed to vapour and the odd splash. I've successfully used JB weld for lots of things in the past - and will probably use it making brackets for my side panels - but thought it was worth going the extra mile (well about 15 to Warwick actually) to get specialised stuff.

I've spent the morning producing piles of swarf and now have the main dimensions turned on my adaptor - cutting a 16 tpi thread and boring suitable holes through it remain to be done.

Ian.
1952 Norton ES2
1986 Honda XBR500

Moto63

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Re: My XBR project
« Reply #102 on: November 30, 2022, 01:29:05 PM »
Top stuff Ian. Looking forward to seeing the tank with it in place 👍
Cheers, Michael

iansoady

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Re: My XBR project
« Reply #103 on: December 01, 2022, 11:39:36 AM »
Thread cut:



The cap in place loosely. The depression where the original flap hinge etc will be filled up to the smaller diameter under the cap itself:





Have to stop now to prepare for a zoom this afternoon. But progress is being made. I'm expecting the new/old sidepanels in the next couple of days and have started away of attaching the front as they would normally mount to the sides of the XBR tank.

« Last Edit: December 01, 2022, 11:41:24 AM by iansoady »
Ian.
1952 Norton ES2
1986 Honda XBR500

Moto63

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Re: My XBR project
« Reply #104 on: December 01, 2022, 11:52:15 AM »
Starting to look the part now Ian. Just wait until you’re pouring the first gallon of moving juice through that monza filler and roarting off down the road 👍
Cheers, Michael