xbr rebuild 2

[JOOLZ]

I have now started on the frame and the other parts, Its fully stripped down now. I found one major problem with the frame, the bracket that holds the oil tank on has snapped (I have no idea how that happened) so it will have to be welded before I respray Im going for a dark red this time. The wiring loom is looking very tatty so I am stripping the outer cover off and re wrapping much more tightly in self amalgamating tape, the parts of the loom I have done are about a third smaller in diameter, so it should look a lot more tidy. I have started making the engine brackets out of aluminum plate, they look great and hardly weigh anything in comparison to the originals. I have modified the throttle barrel to make it a quick action, as with the Amal carb there is quite a lot of cable to reel in. I still have a great deal of work to carry out but its getting there slowly (would be a lot faster if I had more funds to play with) Oh well im used to being skint

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[JOOLZ]

I stripped and cleaned out the oil tank, worth it as I found some metallic pieces in the gunge at the bottom. I have now cleaned it and re assembled with new bolts. I am starting on the frame now, I have already re welded the oil tank bracket back on and given it its coat of primer and the first colour coat.

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[tommy]

neat job joolz where did ya get the oilfiller cap.........tommy

[JOOLZ]

Hi the oil filler cap is from probolt £12 to buy one

[JOOLZ]

I have my shed back, so I have been able to progress faster than before, I can now find all my tools and other bits and pieces. The builders have finished laying the drains for the new house next door so now I am getting things straight in the garden. The frame is finished.

Second pic taken today. Its a rolling chassis at last. I have had to cut back my ideas a bit due to lack of funds, The fork legs will have to wait, their not leaking so im leaving them alone for now.

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[JOOLZ]

Hi the latest progress is that the engine is back in the frame, the engine and oil tank spacers have been made in aluminum now as has the rear mudguard spacers, most of the frame and fork bolts have now been replaced with titanium, the clock holders have been modified and look much neater with the lower mounting height.Iim now starting on the battery box and the holder for the methanol / water injection bottle

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[500 T C]

     Just remember to clean up all the earthing points, before you go any further.

[JOOLZ]

close up of engine

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[JOOLZ]

I have now made the holder for the methanol tank. The bike is very nearly finished now, all I have to do now is get the camshaft reground get an oil cooler and lines, and find a small 12v 3ah battery to fit in the tail piece then its finished

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[JOOLZ]

The camshaft goes off to Joy engineering tomorrow for its reprofile, as soon as its back Im on the road again although Im going to have to limit my fun for the next 500 or so miles as it will need extensive running in and other additional checks. It has taken a year to save up for this rebuild and I am now skint, I have had to skip several things I wanted to do. The forks can see me through this summer, but I still have to get an oil cooler and lines, so I thought I would run it for a month or so without one and fit it later. I only earn £50 a week from my carers allowance so I have to stretch things a bit, thank god Im an engineer and can do most of the work myself. I will put a video up on youtube in the next couple of weeks of the finished bike up and running

[JOOLZ]

Just finishing off the last few little jobs, sorted out the clutch cable bracket. The original attaches to the starter motor.

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[guest1130]

This is awesome! Great work dude! Hopefully I can start posting progress soon on my project as well.

[JOOLZ]

Thanks good luck with your project, it will be interesting seeing how its coming on

[JOOLZ]

Just finished making the new engine covers.   Looks like it all needs another polish again.....oily fingerprints everywhere!!!

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[JOOLZ]

Finally found a suitable battery to fit under the tail piece. Motobatt mbtx4u, its a fiber / gel battery and can be used in any orientation except upside down

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