Welcome to the board ..
New to the forum, thanks everyone for having me. I enjoy TW’s too much. I love them for what they are and are not. I brought this 2004 home with 3,000 miles for $1,700 on Fri 3/16/2018. It was a little rough but I thought it would be fun to putt around the mountain town with. One thing turned into another so now I am attempting a 30 day custom build. A bunch of things popped up while inspecting it after bringing it home, which led me down this road. I hope to keep this updated in the weeks to come and am shooting a detailed video to post on YouTube I will share.
Picture of the plastics off the bike. Day 1
Taking things apart. New stock rubber ordered. Day 2
New rubber, moved bike to the shop to be finalized. Subframe cut off. Day 3
1976 Yamaha XS360 tank came in from eBay. 4+ gallons of capacity. Day 6
New front cups welded on tank. Extended back plate for tank. New subframe spot welded. 23” long. 5” wide at tank base 6.5” wide at tail loop. Using 1” .065 steel round. Happy with results so far. At a small loss for how to handle seat figment at tank base. Will be making the seat pan, electronics box and foam is currently ordered. Day 9.
At this point there is still a lot to do. It’s worth mentioning. I have roughly 20 hours of work at this point not including research. I am a total of $3,000 in the build including the purchase price of the motorcycle. New parts not limited to. Bars. Headlight. Pegs. Grips. Paint. Steel. Tank. Foam. Sprocket. Chain. Blinkers. Rear led tail light. 4 cell antigravity battery. New tires. New rear shock spring. I am forgetting a few other items. I will detail final price and parts list at the end.
I got around to sand blasting the tank today. I will start prepping for paint as soon as I get the custom seat pan and exhaust done. Hopefully will get to these this weekend. Finished welding the rear sub frame and small little bracket to for the PIAA 520 headlight. Day 11.
Anyone have recommendations on wiring this type of plug to the H4 of the stock TW? Basically 2 wire PIAA to the 3 wire H4 harness. I believe the relay and ground are hidden in the PIAA sheath. It would be convenient if I could find a wire harness to just plug in but I doubt it. I will research more on this forum.
I have looked at all the pictures. I hate the old TW is gone but love what its becoming. Pretty cool. Can't wait to see the final product!
TW200 number 2. 2018 1.1 miles when I picked it up.
You have some real fab skills! Looking forward to seeing further progress - The old style tank brings back memories. I had a Yami 250 2 stroke many moons ago with a tank just like that...
Was there any rust that you had to treat in the tank?
Thanks everyone. It is sad to chop the Ol' TW up, I have had several of these and this one was a good candidate to perform this work to.
We'll see how it turns out, I do like the progress but the details will be key!
The old stuff definitely makes you feel nostalgic, which is fun. I am excited about the extra capacity of the gas tank. The tank had some spot rust and one small dent. I will use muriatic acid in the tank and then seal it.
I am still curious about the best way to convert the 2 wire plug, to the 3 wire H4 stock harness. I am trying to leave most of the harness alone on the TW, I am an electrical guy by any means!
Here is another photo of the headlight. Hopefully I will get time tonight to work on it.
Looking great so far. Nice work. Cheers
89 restored SOLD
89 (restoration in process)
05 (restoration in process)
03 10K miles, decent condition
It’s late I just got out of the shop, too much to do.. only two weeks left so we’ll see how it goes. I made the seat pan this evening and need to do the finishing touches. I will have a good amount of foam around the front knuckle i created. Does not obstruct the important bits when sitting even without foam. Battery tray is cut and ready to mock and weld.
Here are updated photos