What have I done...

[AluB]

Hello all,

First post here as a new member, I just wanted to share my story and what YOU made me to do. Lot of information found from this community played a big role during my project. Thank you guys.

I try to keep the story simple. I´m writing this from Finland, so please be gentle with my language skills...

It all started just over year ago. I let go my old friend, Honda VTR modified as streetfighter. She was all fun but I wanted something more. Something different.

I work in aviation as a Mechanic, and also build and restore old aircrafts as a hobby. Warbirds, jets, etc... So when I had to choose my next bike project, it was all by the feel. My background and true love to air-cooled piston engines left me with only one bike. Buell.

From the beginning it was clear that it will be a project. After a while, I found the one. And boy, she was something...



She started her life in 2004 as a bright red XB12R. And after some rough years, I found her like this. Gee...

With all my courage, I bought this one. Without even test ride (it was january and 5 feet of snow outside...)

 

[Cooter]

Wow! I can only guess at your skill set from having such an awesome job :eagerness: I bet that bike is crazy cool in no time.

I'd love it if you'd post pics in Gen Chat of the planes, who doesn't like old Warbirds?!

Welcome to the board, and don't worry your language skills are much better than most Americans :black_eyed:

 

[AluB]

So without any previous knowledge or experience on Buell or even HD´s, I found this... this.... THING... from my garage.



Ok, the bike had Jardine exhaust, "Race-ECU", LSL upper tree and other small upgrades on her. But the look. My god. Subframe, tail and front fender were D.I.Y. And everything was painted flat black. With wall paint I think. And then was the headlight. Old Finnish army gas mask with two halogens inside... Got her stripped down the same evening, just to find this.



Electrics were made from speaker wire. And with couple of knots that Jaques Custeau would be proud of...

 

[AluB]

After stripping all the electrics with a side-cutters, I got the frame out. Engine looked good. No leaks (!), no dents or anything abnormal. And she sounded all good before I started stripping. So the heart of the beast got just good cleaning, black paint and polished ribs.



After couple of days I got her on her feet again. And started to improvise on her future appearance with the headlight first...

 

[AluB]

After cutting all the electrics, I found myself buried in deep sh.... But after long stare-contest with WDM I managed to build working system, using original parts and some new wire. It was REALLY tight, but I got it. Kind of...

With just idea on my head and couple big sheets of aluminium in corner of my garage I began started with base of the "tank".



With a lot smaller air filter, fuses and relays stuffed on the self-made base plate with ECU on top of everything, I planned with paper something like this to cover everything....

 

[AluB]

And it kind of worked! Ugly as hell, but it was to be just a prototype. Made some early plans with cardboard and wires, before ended up shaping aluminum. Desing of the seat came up actually with the original rear seat, placed backwards just after the frame. I think I had couple of too many beers that night...



After sobering out, just cleaned the lines and made base of the seat. To be covered with something softer than aluminum...



Took couple of days to cut and shape the air box. Learning the metal shaping is a long road, that I tried to cut short. And the parts looked like that... Just take your time, patience and A HELL LOT OF TRAINING MATERIAL, eventually you will get it. Kind of... And because I wanted to keep alive my aviation riveting skills, no welding was used.

 

[AluB]

So. With a big rush, called "early spring", the first prototype was rolled out. Unfinished, lot of untested ideas and uncertain condition of engine or electrics. Never a good idea, but you know what. In Finland three months of the year is cold. Rest of the year is just fu**ing cold. Keep that in mind when you look the "prototype." The few first warm days of pring were used to test riding, bike finished or not....





This was the point, I knew I ****ed up. It just looked strange. And after just hundred miles or so, she protested...



Walked her home after my "rush to finish the bike" backfired. Rear cylinder injector got shorted and that was it. She drowned when nozzle was left open and pump kept feeding...

I just gave up. I didn´t want to touch her anymore. At least for the next couple of months... Summer went by and so came the fall, bike stayed in the garage...

 

[AluB]

But then came the day, when it just snapped. I think it had something to do with the beer again. I just couldn´t give it up. Not me. Not with that bike.

So the evolution had begun. First of all, good plans. Make them. What are you doing, why and how. I had just one plan. Make it look like a Warbird, because it sounds like one.
Get all the parts you need. Just get them, before you start. When you select your parts (or make them), stick with your plan.
After these two, just don´t take shortcuts. Just don´t. Study if you have to (here YOU people trained me even not knowing it...)


Airbox cover got new desing, now with proper wooden buck.


Frame got new paint, polishing and aluminum side covers.


Swingarm got polished, so as front fork. New design of side scoop was introduced...


After all the parts were made, bought, introduced to each other and teached to behave in one group...

 

[AluB]

I ended up with this.

 

[Cooter]

Whoa.

Thats really really impressive! Well done:very_drunk:

 

[AluB]

That it. She´s not finished yet, needs small tweaks here and there. But what we have here currently is,

Buell XB 12R -2004
Jardine Exhaust
Tuned ECU
K&N Filters
Stock chassis and frame, just minor modifications made (to make sure that everything can be returned to original state)

LSL upper tree and footpegs.
Pulley cover from RR customizing
Low profile handlebar
Front brake master cylinder and cluth lever frame from Yamaha R1 (because R1 uses Brembo radial cylinder, the feel of the brake is just sweet...)

All lights are LED´s. Locally found. So as other smaller parts...

Hand made: Airbox and scoops, frame "covers", seat and subframe, cooling air scoops on both side, front fender, headlight cover... and lot´s of other stuff. All out of aluminum. And everything is riveted together.

All the electrics are made around Motogadget products. Speedometer, handlebar controls, M-lock, M-unit blue. LiFePo battery is hidden inside RAM air passage, inside the left side of the frame. Works well. Engine wiring was rebuilt, and currently controlled with Buelltooth. So actually everything in this bike can be controlled with a phone.

It´s handmade and looks like it. I think it is first bike that will be "waxed" with scotch brite...

How is it on the road?

Riding position, chassis and all possible controls were left as close as possible to original. But with that seat and all unnecessary removed from the bike,

I´m scared ****less and smiling at the same time... It´s fun. You people know it. Motorcycle is made to create big feelings. This one does.

Over and out.

 

[34nineteen]

Since you said it could be returned to its original state... are the "holes" in the frame just graphics?

Looks really good, nonetheless.

Do you have a closeup of gauges area. The more I look, the more I like it.

 

[Cooter]

Since you said it could be returned to its original state... are the "holes" in the frame just graphics?

View attachment 13297
Frame got new paint, polishing and aluminum side covers.

YOU ARE WRONG!!!!









:angel:

Sorry AluB, this is going to be a forum joke for awhile....

 

[mike lowary]

YOU ARE WRONG!!!!









:angel:

Sorry AluB, this is going to be a forum joke for awhile....

Holy hell thats funny!

 

[34nineteen]

Holy hell thats funny!

ITS NOT FUNNY WHEN THE JOKE IS ON ME!!!!!!!!!:mad-new::mad-new::mad-new:





(ok maybe it is).


AluB - I missed that about the aluminum side panels. Holy carp thats nice!!!!

 

[Endopotential]

That bike looks amazing! I love the riveted look, it really does make it look like one of your warbirds.
I think some people have painted / modified their mufflers to look like a belly bomb or drop tank. Probably too cheesey for your refined tastes :eagerness:
You've got remarkable skills in fabricating parts.

Our bikes look great with lots of shiney bits...

PS Your English is more than fine. Actually embarrassing that you write better than most us Americans :black_eyed:

 

[chief_of_smoke]

Looks good. Definitely better than what you started with.

 

[mike lowary]

As a metal guy I really appreciate the effort that went into this. I have a build in my head that includes lots and lots of raw aluminum. Good job man. Looks great.

 

[njloco]

It's very different and, not that it matters but I can't tell if I like it or not, it reminds me of the Tin man, " a metal guy ".

 

[AluB]

Thank you guys, I´m glad that it makes smiles on peoples faces.

About the questions,


Yes 34, YOU WERE WRONG! It´s just "make-up" panel. The holes actually work as a flange to make the panel more rigid. Aircraft wings are built like that and the Buell´s frame sideview looks like a wing rib to me...



Closeup of the instrument panel. Motogadget Speedster, attached to upper yoke with simple bracket. Two added side LED´s are LFW and Oil press (marked currently with F and O just as a reminder). Speedster has built in lights for ENG light, HI-beam, neutral and turn signals, as well as clock, odo, trip and voltage info. Lot of stuff in small package.


One of the "what if..." ideas. Lithium battery found it´s nest inside the frame. I just made tight-fit package with fire proof materials (just to give me a minute of reaction time in case of electric fire...) except the removable cover. Yes, only lunatic installs "possible fire if overheated" -battery inside a fuel tank, witch will be heated by engine. But the same lunatic climbs daily inside a machine, that goes hovering thousand feet high while the machine tries it´s best to shake all it´s parts away. Compering these two, i´m willing to take the risk of battery fire and exploding frame. If it happens, at least i´m on ground level...


Overall on main electrics. Needs to be cleaned and organized, it will happen after I´m sure that everything works. Also somekind of intake baffle will be made to keep electrics clean and dry. But you get the idea. The m-unit is a "must have" if you want to make simple system with smallest amount of wires possible. That small "snake nest" is actually 80% of all the wires on the bike. Everything is covered with green kevlar shield, leftovers from work...

And about the muffler as a belly tank... That actually was one option. What do you people think? Should i build a belly pan, modify the muffler to look like belly tank from aircraft or keep it like that and shave the unnecessary brackets off? Opinions?