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Old 02-18-2013, 03:39 PM   #31
LisaS OP
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Had a few weeks away from the project- Jerry had a weeklong conference in Cincinnati and brought home a lovely cold to share with me- it's taken a couple of weeks to recover, but we are not back to work. Pics are uploading from the most recent mod.

Quote:
Originally Posted by TwilightZone View Post
Billet gas caps. I bought mine from Rocky Mtn ATV. Shown is Clarke tank model.

http://www.rockymountainatvmc.com/p/43/53/213/1367/-/8590/Tusk-Billet-Aluminum-Gas-Cap-Clarke-Fuel-Tanks/tusk+gas+cap
Those are really pretty- I think the blue would really tie the tank together with the rest of the bike.....

Quote:
Originally Posted by Skowinski View Post
Nice work. And, looks like you have quite the help crew there, between your husband and the cat you've got it covered!

We have a friend who bought an XT225 to learn to ride on. Need to put her onto this thread to spark her up.
Thanks. The cat is definitely the hardest worker of the three of us The xt is definitely a great bike to learn on- nice and light and not too tall!
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Old 02-18-2013, 03:53 PM   #32
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Ok- I do tend to take a lot of pictures, so I apologize in advance for the number of pics in the next segment. The rear fender took a long time and quite a few sessions in the shop... so the number of pics reflects that.

I know everybody knows what the back end of an xt looks like, but here is my before pic anyway!



I liked the looks of the fender in the foo fighter project, so Jerry found me one.... It in no way resembled the original.... At all..... It took A LOT of fabricating to get it to fit the bike.
So hear I am cutting all the extra plastic off:


hmmmmm....


My license plate holder is going to obscure the taillight and this is not the same tail piece as on the foo fighter bike:



I don't intend to do a lot of street riding with this, but when I do, I want to be seen!
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Old 02-18-2013, 03:59 PM   #33
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Ok, now have the correct tailpiece, but it looks kinda bulky back there:


At least now the license plate holder will not obstruct the taillight:


Crookshanks approves!


And I know what to do with extra plastic!


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Old 02-18-2013, 04:12 PM   #34
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Next up is getting the tailpiece to attach to the fender.... then to get the fender to actually attach to the bike (without zipties!!)

There was a bracket on the back of the frame that the original fender attached to- that came off- then needed to be ground smooth:




ok... I am not a big fan of flying sparks landing on my bare skin.... I am learning to weld and can now make a sort of bead without jumping when the sparks fly, and I can wear gloves and cover up pretty good... however, gloves and power tools don't mix, so I let shoein take over the rest of the grinding (he makes way prettier sparks):


And now the frame looks pretty:


I know there is nothing making sparks in the next pic, but I let Jerry do this anyway as he has more experience with the tools and I did not want to mess up the whole fender- there were two small pieces on the underside to come off:


"ummmmm, guys, I think there is something missing here!"

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Old 02-18-2013, 04:21 PM   #35
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Jerry thought it would be a good idea to utilize the brake light from the original tail piece:




Then there was the matter of attaching the tailpiece to the fender. Jerry decided to try some glue on shoe adhesive prior to bolting it:




It held things together long enough for us to finish fitting things to the bike and figure out where we wanted to bolt things together, but then separated once we started with the first bolt.
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Old 02-18-2013, 04:27 PM   #36
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next up was a new bracket for the new fender- this one on the inside of the frame. More sparks:










and a little paint (once it dried, it did not look bubbly like it does here):

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Old 02-18-2013, 04:49 PM   #37
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There was quite a gap between the new bracket and the fender- Jerry did not want a lot of empty space there, so he used some hoof composite material to make a spacer- I was able to check the fit using the camera (what did we ever do before digital?)


It will set up to hold the shape, but is not brittle:


Here we are getting ready to bolt things up:


I'm a bit worried that the cat may have mutated after sniffing the hoof glue and composite:
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Old 02-18-2013, 05:02 PM   #38
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Once the mutation wore off, and Crookshanks got back to work, he and Jerry had a little staring contest:


This is the bolt that will go through the composite and the new bracket:




After we got the fender bolted on, the tailpiece still felt a bit wobbly- Jerry burned the hole instead of drilling as right below this a small space and then the taillight housing:


And the (almost) finished fender (still going to add a second set of turn signals as the ones on the tailpiece are very close together AND I am going to put my storage/license plate holder on AND we still need to wire everything up back there):





Ok, now on to some front end re-fab!
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Old 03-01-2013, 12:42 PM   #39
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Fantastic build thread!

SpawnOfEC has an XT225. Great bike! She even let me take it out for a DS ride last fall. What a hoot! Thought about one just for camping - nice and light to hang off the back and it'll go anywhere you're willing to point it.

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Old 03-04-2013, 05:23 AM   #40
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Quote:
Originally Posted by EvilClown View Post
Fantastic build thread!

SpawnOfEC has an XT225. Great bike! She even let me take it out for a DS ride last fall. What a hoot! Thought about one just for camping - nice and light to hang off the back and it'll go anywhere you're willing to point it.

Thanks EvilClown.
I haven't had a chance to ride this bike yet, but I really enjoyed the previous one I had. Not too much longer until riding season (hopefully)!
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Old 03-04-2013, 05:24 AM   #41
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We have been working on the front end for the past couple of weeks- this has required quite a bit of fabricating and new wiring, but finally got it done yesterday!

Before Pic:


New Front fender:
Holes did not line up, for attachment, so needed to make new ones- the bike is smoking again!


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Old 03-04-2013, 05:38 AM   #42
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Turns out I could not get the new fender attached as the tubing for the front end wiring was too bulky- so we needed to get the headlight off and start thinking about the wiring a little sooner than planned.


I marked all the wires on the bike using painter tape so I would know where things plugged back in and made these notes.... I was pretty skeptical that we would ever get this wired back up correctly again! (Especially since we needed to add wiring for a second set of turn signals up front- amazingly, this worked quite well!):


Here you can see all my little blue tape labels on the wiring as well as how the new front fender looks on the bike:


The back side of the fender was quite a bit longer than the stock fender:


So a little trip to the band saw and grinder and voila!


And a preview of the new headlight....
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Old 03-04-2013, 05:52 AM   #43
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The front fender was now on, and the tubing issue taken care of, but now the headlight would not sit properly as the odometer/turn signal unit was in the way. So we decided to remove it, separate the odometer piece from the turn signal piece, make new brackets and relocate the the two piece so the headlight would sit properly. Our friend Krissann stopped by, so she got recruited to help on the bracket fabrication:


















Under very close supervision as usual:






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Old 03-04-2013, 06:04 AM   #44
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So the odometer unit was successfully relocated, now for the turn signal unit- which still has the original odometer bracket attached:


So back to the band saw


While Jerry starts fabricating another bracket:










Plenty of room now for the new headlight:


However, not so cool with the wiring sticking out the front:


Out of pics- to be continued.....
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Old 03-05-2013, 08:04 PM   #45
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Nice job. Enjoying the build. I hope the bike & mods work out for you.
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