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Custom bikeporn addict.
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Discussion Starter · #1 ·
OK so I just picked up a new project bike, well semi-project bike. I need a good running bike again and with the ex500 needing random parts and work I figured it'd be a good chance to overhaul it or part it out if I get too frustrated.

So I wanted a commuter, and I found this.





Headlight is in good condition and still works so I'm thinking I can cut down the cracked up front and mount it to the forks like a Z1000. Then look into the reality of all the rest of the modding.

I found some great inspiration :



Doesn't look like just cut down sides, I emailed the company to get more info. I may be crazy but it looks like the lower fairing is actually a tail fairing that was modded. I have a cbr1000rr tail at home that I can use to mock that up to see if it looks right. Can't afford a nice usd front like that but I have a FZR600 front I can swap on and maybe a fzr600 rear for matching rims.

Anyway, I'm really hoping I can make it work. A Z1000-mini would be sweet :)

Bob
 

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Custom bikeporn addict.
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Discussion Starter · #2 ·
OK so I started with the hacking.

Chopped up one of the sides to make a scoop-like cover. Mostly to hide the tank mounts and to hide the rad overflow on the other side.







And the headlight mockup. Using the stock headlight and making a small visor out of the stock fairing. Still have to cut down the stock windscreen along one of the mask lines, still haven't decided which one.



I have some bar clamps coming from ebay so I can put dirty bars on. Stole the bars from the ex500.

I put some clubmans on the ex500. It looks way better. The cafe theme just works.

Anyway. Still a bunch to do. Thinking maybe some metal mesh to partly close in the scoops up by the triple. Thinking of mounting turn signals on the points of the scoops, like a Z1000.

Ordered clamps to mount the headlight on the 250 from mcmaster, hopefully I can have that thing on the road withing 2 weeks. I'm dying, havent ridden for about a month! I'm sick of having no ride.

Bob
 

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Custom bikeporn addict.
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Discussion Starter · #4 ·
Cut that headlight along the lowest tape line and I will make sweet facelove to your bike.
You better buy it dinner first. It ain't no slut! It's a high class whore hehe.

Bob
 

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VTR fighter
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Cool good progress keep it up :)
 
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Winter's comin... :(
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I like how you did the side panel(s).
 

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Discussion Starter · #9 ·
Dun did mo wurk!



Cut some triangles out of what was left of the side fairings to make the inside of the scoops a bit cleaner. This was during the melt fest. Gonna have to steel wool the hell out of my soldering iron.



Here is after sanding. Still need to smooth out the edge so it looks factory finished. Smoker and Cabbie's builds really got me feeling like I could do more to push mine to look more finished :)

And a couple of the rough finished pieces mounted. Still need a little heat gun tweaking.





The stock speedo cluster is way too big. Gonna have to do something about that. Also, I think I'm gonna find pair of flushmount cheap turn signals to mount on the tips of the scoops.

As it stands it will at least be street legal for now. Just want to get back on the damn road. Been way too long.

Bob
 

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Custom bikeporn addict.
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Discussion Starter · #10 ·
Anyone use those thai made ebay headlights?
I think this one:

would really work well with the bike. $30 shipped, sounds too good to be true :(

Bob
 

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Winter's comin... :(
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It's probably poor quality plastic, but that's hardly an issue. The bulb will probably burn out quickly, and you should then replace it (and the lighting socket) with normal H3/H4 hardware.

I'm sure if you don't keep on it, the lens will fog up pretty quickly too.
 

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Discussion Starter · #12 ·
It's probably poor quality plastic, but that's hardly an issue. The bulb will probably burn out quickly, and you should then replace it (and the lighting socket) with normal H3/H4 hardware.

I'm sure if you don't keep on it, the lens will fog up pretty quickly too.
So what you are saying is that it's a great deal and I should buy it!!!

I hate it when the " you get what you pay for " adage is true. It goes against my cheap nature.

Bob
 

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Winter's comin... :(
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So what you are saying is that it's a great deal and I should buy it!!!

I hate it when the " you get what you pay for " adage is true. It goes against my cheap nature.

Bob
Try it out, dude. $30 shipped is like... a case of decent beer.
 
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Cmon' Kitty!
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Discussion Starter · #15 ·
Try it out, dude. $30 shipped is like... a case of decent beer.
JW dundee has a sampler 12 pack that's about $11. AND it's really good beer. So I may potentially be out 3 CASES OF BEER! I mean we're really upping the antee here. 3 cases of beer, 36 delicious beers. Are you willing to gamble that? And not to mention the cheap gin. Gin and tonics are my favorite mixed drink. Gotta have the tonic water with quinine though, plain soda water doesn't cut it.

hmmmmmmmm. This will require more though. See if I can make the stock one work first.

Bob
 

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Are you really rationalizing beer and gin?

OMFG...
 
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Discussion Starter · #18 ·
It's coming along slowly because it has become my daily rider. Current plans are to put an FZR600 front end on it, mostly because I have it sitting in the basement. See if I can easily swap on the FZR600 rear wheel, it already has a 520 sprocket on it so hopefully it will be easy. Then probably cut up what's left of the OEM fairings into a belly pan, the headers are kinda awkward the way they swing out and back. Also hopefully new ebay speedo from a CB soon then I can fit the front fairing top better so it looks clean. Probably make some side covers/brackets for the headlight to make it look better from the side.

Finally I gotta decide on paint. I like the green and all but I dunno if I wanna keep it that way. We'll see.

I also have to pull the air mix caps and tune the carbs a bit. The low end is far from smooth, after about 7k rpm it runs much better though.







Bob
 

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the rear wheel issue will be width of the rim, not what size sprocket it takes. see how much room you have for clearance within the swingarm.

bikes coming along, but i think it needs some paint. the black hides the body work that is there, so it isnt really showing the eeffect you were going for imo.
 

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Discussion Starter · #20 ·
the rear wheel issue will be width of the rim, not what size sprocket it takes. see how much room you have for clearance within the swingarm.

bikes coming along, but i think it needs some paint. the black hides the body work that is there, so it isnt really showing the eeffect you were going for imo.
I have the whole swingarm and rear wheel along with a few other swingarms to play with. I'm hoping it just bolts in. If I remember correctly Stunt's Turbo 250 used a FZR600 rear wheel, though actually I think he used the swinger too. But ya. Probably a buncha headaches in the future.

As for the paint. Agreed. I couldn't really put a finger on it but what you said really makes sense. Now that I look at it, it looks like there are only green fairings and a black blob under them. Maybe I should go white, make it look more like a Z1000.

Thx
Bob
 
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