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Project / Build: Yamaha XJ Bobber
We have run this little XJ550 bike for
the past 12 months and its been joy to ride it.
With other projects now complete we got bored, looking for another bike to do
and wanted to create something different.
This one was sat in the corner of the workshop minding its own business after
being one of our project bikes back in 2006.
We decided to introduce it to Mr saw and Mr grinder! This will make a nice
Bobber we thought, so lets see what develops...
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How the bike stands after the first restoration back in 2008
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Photo history
The Strip down
for Phase 2 - Custom project..
Work begins May 2009. Strip the front end for yokes powder coating and
polishing.
Cut down and reshape the seat, chop the back end off.
Strip the switch gear, stripped and coach enamel painted.
Wiring loom to cut back and relocated. Engine rebuilt and painted
We wanted to
keep the lines of the original fuel tank, but its the wrong shape!
No worries, we "duffed it up" it into shape with a piece of 3 x 2 and a hammer,
and hit it with the body filler ready to create the final shape.
Still
on the go, fitted with old skool T-Bars to get a better picture and feel of the
bike.
Top and bottom yokes coach enamelled super smooth. Fitted mini speedo and
fabricated the mounting brackets for the Bates headlight.
Re located the horn and started to replace every nut, bolt and washer with
polished stainless items.
A new smaller, fatter rear wheel is to be fitted which we are working on some
spacer mods to make it fit.
More work on the wiring loom to keep the bike clean of the clutter.
Tank now
reshaped and smoothed, primered up ready for paint. Front forks mirror polished
and flamed.
Side panels made and ready for polishing. Cables and wiring loom re-routed. All
wiring heat shrunk.
Side mount tail light / plate holder custom made and fitted.
Front cruise peg mounts custom made and fitted. Mid foot peg brackets enamelled
and custom pegs fitted.
Rear wheel painted and polished. Seat re-shaped (again). Mirror Polished brake &
clutch levers fitted. Custom flame mirrors fitted.
Painted Tank and
front fender. Black base coat and Silver custom flames, then silver metal flake
and finished in clear coat.
More polishing on the side frame 'A' panels.
Waiting on rear fender (not 100% sure which to use - watch this space)
Front end now
complete. Painted and polished front wheel, brake callipers refurbished and
finished in Satin black.
We get to work creating the exhaust system - 2 short fully open side slash pipes
either side!
Looks nice and sounds awesome.
Working on the
rear fender. We used a 6.5 inch Galvanized trailer fender, cut in down and
trimmed off.
We decided to make the set - up as a 'hard tail' look but with with soft tail
suspension!
The guard is welded directly to the swing arm at the front and held at the back
with our own custom made upright stays.
Everything is mocked up to ensure a nice fit around the rear tyre, then sanded
smooth for paint.
Finished (as everything else on the bike) with polished stainless Bolts, Nuts &
washers.
The final touch is the rear guard emblazed at the lower tip with our own custom designed shield badge.
FINAL PAINTING AND POLISHING COMPLETE.
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>>>>>
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