My 454 bobber/chopper

[bwhittet]

So it has been too long. My project sat all last year due to the house renovation. Also it was sad to see this forum have its battles but I'm glad its back up and running strong. Wish my project was.

I'm back to working on my bike (about f-n time.) I see a few new faces here so I'll give a quick recap of its morphing.

So purchased a basket case 86 454 back in late 2006. Thought I might bob it out. Dented, rusty, and not all there.


The engineer in me wanted a wider rear tire. So i found a kawasaki ZX600E rear wheel that looked like it might work with the 454 belt crush drive.
This is where I started to dig myself in deep.
 

Switched bearings, made new bushings/spacers, modified crush drive, and more to get wheel in and belt to line up.
I like the look but now I'll have to switch to disk breaks in the rear.


Started thinking the front should look more like the new rear. Found a 90s Suzuki katana front that had similar rim style.
So i cut apart the 454 triple tree and grafted its steering shaft into the katana triple tree. Now front looks better.


Needed some risers for the handlebars so made those.


Needed to make the new rear disk break work with the foot controls so made a set of foot controls.
Problem these would require cutting off old control mounts and weld in my new ones. Now the frame mods start.


I like the new rear tire but with those shocks there the tire still seems small.
What if i did a mono shock. Could it be done?


I should have been slapped long before it got this far but here the mono shock idea starts to snowball.
Found a shock to maybe used and tack welded mounts in to see if it might work.
Now its too late. I love the look. Now a new set of problems. The shock reservoir and tire inter-fear. Maybe longer swing-arm and remote reservoir. 

I found a shock with remote reservoir, an EN500 swing-arm, and belt. Now to make it all fit.
Started chopping off all I didn't need and want. Also started smoothing out factory weld seams.


Now started adding the stuff i would need.
Foot controls.

Rear suspension.
 

Bolt on seat frame.


So far looking good.

Needs kickstand.

Needs battery box.


And this is now it ended 2009. Three years of puttering around on this 454. I like it but it is still not road worthy.


Sad to say 2010 had no real progress. Much like the bike a house project transformed into a full renovation. I'm still not done with house but its livable again.
So now in 2011 I'm giving some of my house time to the 454. Not much but some is better than none.

I need to make a seat. I'm also starting to look at the wiring of this bad boy. I think i might strip the wiring down to just what I need and I'll add back circuits as I go. So the search for a harness to use, and other components goes on.

Later,
Brian

[eaglerider]

;D Thanks for bring ur project up to date, and re-posting things. Yes, we have had a number of "setback problems", but ya know how hard it is to keep something good down! We are back stong....with both old and new, and new to motorcycleing members. the new ones, are gonna need a considerable amount of help, so we will do our best not to get "aggrivated" due to the "old", and (to us oldies) obnoxious questions. LOL Glad to see ya back, Brian!!!

[rehabforquitters]

Great Work. I hope you get it road worthy soon. Would love to see the finished product.

[robertg]

Can't wait to see it all done. I had just told my wife that I think I'm going to sell the 454 for some extra cash, plus I didn't think I had the time for it. Now after seeing this, I decided to keep it and just work on it when I have time. I love the whole mono shock idea. That looks awesome.

[fragman565]

love the momo shock idea i cant wait to see it all done

[osttrefftwest]

I'm glad to see you're still out there — I've Googled you from time to time, hoping for progress updates. Still love everything so far, and can't wait to see how it comes out in the end!

[bwhittet]

New straight pipes.

One shown assembled on bike one disassembled in front. Piece of mesh to show what the fiberglass packing is wrapped around.

Main part of pipe is made of 1-3/4 OD 18ga tube 22" lg.

Baffle is made from 4x4x.023 sst mesh, 1-1/4 OD 16ga tube and some scrap parts from work to form the tip and spark arrestor end.
These homemade baffles are a copy of Vance & Hines Big Shots/Python Quiet Baffles. www.motorcycle-superstore.com/3/13/118/17604/ITEM/Vance---Hines-Big-Shots-Python-Quiet-Baffle.aspx

Short piece of pipe is a thick pipe turned down to fit the ID of the 1-3/4" tube. This gets welded to the end of existing exhaust to provide a tight fit to clamp to.



Have not run it yet so can't say how they sound. Busy reworking wire harness

[wanchesenative]

Glad to see you back. I was wondering what happened to this project. I think it's awesome and can't wait to see the finished project.

[ice cream man]

WOW, I am sooo turned on right now!

[ridgerunner]

Those are some sweet DIY exhaust. Hopefully you will be able to share a sound bit when she is up and running. The bike is looking awesome

[bwhittet]

Slow progress as usual.
My next step was wire harness. I drew a schematic out on paper. Then thought I'd see if my ideas would work. So thought I'd share pictures of my mess I threw together to test my wiring plan.


LOL. what a mess.
Did it work? Not at first. Sprayed carb cleaner in carb boots to see if it would fire. Nope just backfired and started a small fire in carb boots. ;D Switch coil wires around and it fired right up. Yeah plan works.
Now to mount all the components and clean up my wiring.

Here is a picture of the starter solenoid, starter relay, and fan relay mount I made. I band saw cut some stainless sheet steel to match the tabs of the stock mounts. Then formed it and bolted it down under the carbs. I'll have to take a better picture with it out and everything off it.

 
So this weekend I'll bolt down my components and clean up the wiring on the harness. Maybe I'll get to start on the fiberglass seat pan that will cover the components under the seat.

[sctsgt]

Brian,
How goes the campaign? Your beast was the one thing that I truly missed seeing progress on while I was away. Looks awesome so far, can't wait to see the finished product.

[bwhittet]

Not long after my last post my wife and I decided since we were expecting our first child in March we had better re-insulate the baby's room. (100 year old house.) So October through January we gutted two small bedrooms and a hallway of their plaster lathe covering. Shimmed and firred old studs. Relayed out doorways and closet locations. Rewired the whole area. Had the stud cavities spray foam insulated.

Middle of January I was sheet rocking when my son came TWO months early at 2 lbs 13 oz. Hired a friend to finish drywall. Sanded the painted floors and refinished them. Floors finish and wall paint was finished end of February. My son Henry came home from the hospital first of March weight was 5 lbs. Now the end of March if I'm not learning and enjoying being a new dad I'm trying to finish up more of the house.

My son is doing great. He was originally due March 20th. As of now he is almost 7 lbs.

Bike is in back of garage under its cover. Weather here in Minnesota is warming up. Soon I'll switch the snow blower and bike places in the garage and pick at least one night a week to work on it again. I had the most of the electronics bolted down and was well into creating my harness. Still need to mold my seat pan and upholster it.

I'll keep my progress posted. Sorry but the bike got put on hold for a while. I've enjoyed checking in on you guys and envying those out riding.
Later,
Brian

[ibuiltmine]

you know what sucks is your going to have a 500 ninja when your done. Well, not really, but....

I have a 1200 sporty that I am fitting gsxr forks and wheels and brakes onto, and I sold my Buell XB to do this project! Factory sucks. I like factory bikes but Ill build my own, thank you!


dont stall the project, it looks awesome.

[chopperfreak2k1]

hey B! congrats brother! a new baby is always awesome. glad to hear the good news!

[Blaine]

Congts on your new addition. ;D

[bikerdave]

Congrats on the little guy! better get that bike done,Before you know it he will wanna take it out for a cruz.

[eaglerider]

;D I add my congrats! Hey, don't worry bout it, gotta put more important things first..enjoy being a Dad!!! Make time for the bike project as time permits, but yeah...better "git er done", so u get to ride it before that young feller wants to claim it! Those young'uns grow up awful fast...I know, I raised 5 sons!! LOL

[sctsgt]

Congrats on Henry!! Don't worry about us, just do your thing and when you have time to work on the project go for it.

[Pooh]

Congrats on the little biker

[bwhittet]

Thanks for the congrats. I'm very excited starting my new job as DAD. Amazing how much I love him already.

I will keep you posted on the bike. I want to see it done as much as you guys, if not more.
Thanks again for the interest, the support, and the congrats.
Brian

[wanchesenative]

I'll add my congrats to the many you've already received.

[bwhittet]

I hope to have a running bike soon. Not street ready but maybe running.

Been working on wire the harness on and off between my new dad duties. Got the system wired, soldered, routed, and loomed so it could run. I still need to finish wiring the headlight, brake/tail, blinkers, and horn.

Anyway wired so I could maybe start and run it. Last night thought I'd try and get it started. Bike has been sitting mostly dry of fluids for a couple years now. Here is a list of the fun I had last night.

Attach Carbs... Installed cables on to carbs and had the choke cable break.

Oil... Could not find all the oil I swear I had. Only found 3/4 quart so I was not able to fill it.

Coolant... Attached and tightened all hoses. Added coolant. After few minutes noticed wet spot under bike... Coolant leaking from water pump. Tighten bolts and hope gasket will seal up. Probably sat dry for too long.

Gas... Tank has been stored full of gas with stabilizer in it to help keep tank from rusting. Gas is not the best to use so grabbed an old lawnmower tank i have and hooked it up as a temp. Added fresh gas to temp tank and discovered I forgot to shut the drains on the bottom of both carbs. Shut drains and clean up gas spill.



Maybe this weekend I'll get it started. After I pick up oil, order choke cable, and hope pump gasket holds. Figured I better find out what it might need to get it running smoothly now.

After that.... Fiberglass seat pan needs to be made. Mufflers need mounts made (hopefully mufflers are not too loud). Wire and mount tail light and blinkers. And more...

If you read this far sorry there is not much for progress to show. Just letting you guys know I am working on it.

Later,
Brian

[carpaltunnel]

Inspiring. Your skill in fabrication to make the bike exactly what you want is what I hope to achieve. I'll be creating my own forward pegs and eventually link them as controls in the coming weeks. Good stuff, keep it up!

[wanchesenative]

Just glad the new baby didn't make you abandon the old baby. Can't wait for more! But I guess I'll have to. LOL

[bwhittet]

Oil and coolant topped off? YES
Wire harness reworked so bike might run? YES (no lights yet)
Small wedge of wood holding choke open because cable broke? YES
Does it run? YES (only with choke on)
Does it need a lot more work to get it on the road? YES


Click on pic to take you to video.



Still to do....
Finish wiring for all lighting. (head, tail/brake, blinkers)
Make mount for license plate and taillight.
Make fiberglass seat pan and upholster it.
Get running right.
New tires.
New seals in forks.
Build mounts for exhaust pipes where frame turns upwards toward seat frame. Right now exhaust just hangs from header pipe.

[stormoffires]

what type of air filters did ya put on there? Ive been trying to think of a better way for the air system it just seems shotty.

[wanchesenative]

Lookin' Good!!!

[chopperfreak2k1]

very cool brother! did you change the size of your rear tire? if so what are you running now? you had mentioned this long ago but i can't find it in this thread. thanks!

[bwhittet]

170/60-17 is the size I was able to shoehorn in. There is no room to go bigger that is for sure. No I did not list the size in this thread. The old thread had all the info how I got it switched in. I love the size and look but it snowballed into a lot of changes. Mainly the forward controls.

Started right up last night. I've been working on the brakes. The donor front end had really gummed up brake hydraulics. Got one side all cleaned up.

Spent the weekend fixing my truck. Rusted brake line in frame rail behind fuel tank. Too much rust. 230k miles in Minnesota can take a toll on metal. Truck is fixed so maybe back on bike tonight.