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Discussion Starter #1
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
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Taking things apart. New stock rubber ordered. Day 2
3BE41C1D-FF16-4337-834C-0D0EAD204C16.jpeg EA7BE3C1-92A1-4BA6-AC0C-99E58D52E02A.jpeg E587D398-8142-4536-AC23-4C620678495F.jpeg

New rubber, moved bike to the shop to be finalized. Subframe cut off. Day 3
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1976 Yamaha XS360 tank came in from eBay. 4+ gallons of capacity. Day 6
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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.
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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.
 

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Discussion Starter #3
30 Day TW. PIAA Headlight and finish welding

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.

AFCDBE60-9BFE-454F-8F1E-66E9EBF72BC3.jpeg 44EA0FCB-FB0A-43DD-AA22-46F1766482A1.jpeg 14B34E76-D126-4D06-9057-6CBD214F0655.jpeg 133F1B22-80C5-4596-8EE9-996B9F2D6BB5.jpeg 2BFE3FC2-FE7D-416D-BB1F-50948617E475.jpeg 21E42553-1880-4994-8F14-F14E685EA009.jpeg
 

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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!
 

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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?
 

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Discussion Starter #7
Update

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.
TW200.jpg
 

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Discussion Starter #10
Day 12/13

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 :eek: when sitting even without foam. Battery tray is cut and ready to mock and weld.

Here are updated photos
F9898F2A-DF43-47D3-9C29-D8781487A800.jpeg DBEBBA81-6771-47C3-BAF4-965276F2EA45.jpeg 1C2B3E2B-8D6F-4DFE-99A8-587202B77734.jpeg E496F5CC-FA03-471C-81E8-3B88B04CD478.jpeg C00D8C6D-01A1-43BF-90F2-334BAF56FBC4.jpeg
 

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Discussion Starter #11
Need your advice: Muffler

Anyone's opinion on this exhaust placement is welcome. I don't believe I will have any bags or side cases. There will not be any passengers.

Ex1.jpg Ex2.jpg Ex3.jpg
 

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I like the top picture.
 
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I like the bottom one too. Have you thought about running it under the motor?
 

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Discussion Starter #19
Thank you for the feedback, the last one it is. If I was doing my city riding I would consider an under exhaust but this TW will be in the mountains.
 
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