This seat marks one of the final steps in this build. I recently got all the parts back from PC. My tank will be done soon. I finished wiring the bike last night and everything is working! Haven’t tried to run it yet, need to do a little more buttoning up first. But I’m very, very close!
I’m VERY excited about this build.
I finally took some time to look closely at the gas tank and see what all I need to do before it can be painted. It isn’t too bad except for this huge dent on the left side.
I do not feel like filling that big ole thing with body filler… So I cut out a square section from the under side of the tank and started hammering and such. Within a few minuets I had this.
Obviously still some work to smooth it out. But nothing like it was before. I welded the square back in place and it is like it never happened. Awesome. Hopefully I’ll have this thing ready for paint in a few short days.
After much indecision about what to do with the exhaust on The Mullet, I decided to stick with the theme and do a twisted take on an under-tail exhaust. Except I wanted more of an IN-tail exhaust. I got lots of 45 and 90 degree bend SS pipes and started mocking something up!
This is what I mean by “in” tail. We’ll see how it turns out.
Here is the rear cylinder completed.
Don’t worry, I slipped these 4″ baffles in each pipe to insure back pressure as well as keeping it at a reasonable tone.
Okay, got them all mocked up. I welded them all together and will wrap them with the best exhaust wrap on the market. The Lava Titanium wrap. it isn’t fiberglass based, it goes on easy, retains its metallic luster, and withstands heat much better. I think it will look killer!
Now I need to fix up the tank for paint.
In keeping with the spirit of this Virago’s oddity. I decided to try out using some white vinyl Sam gave me for the seat. What do you think? (Imagine the sub frame being black…and bike being clean!).
Also got the rearsets all plumbed, feels good to sit on.
I really need to clean this bike up…!
I keep hearing that this bike looks like something out of Mad Max…I disagree! And I’m sure this piece I just made for it won’t help my case…
I took some straight steel stock, like this.
And shaped it into this. Then cut some perforated metal out and welded it in from behind.
Not going to lie…I’m pretty proud of this piece. It took me a good hour and a half to create. But I think it will really tie the bike together.
I had to put this bike on the back burner for about a month to build Misty’s CM200t for Bikes Blues and BBQ. Now that I’ve got that bike done (in record time! I might add) I can re-focus on this sweet adventure bike. So to celebrate Remy’s revival I busted out this intake manifold for it.
I welded it out of some mandrel bent stainless steel. I love this tubing! I just stocked up on it because it welds like a dream and is so well finished. This intake took about 30min. Simply welded 2 90 degree pipes together, holed the center/ side of it and butt welded a 45 degree fish mouth onto it. When I bust out the Caswell for the tank, I’ll dip the intake in it as well to give the manifold a nice, sealed, gas impervious gloss black finish.
There were some clearance issues with the brake caliper and the bolts that hold the disk on. So I got some tapered bolts and a countersink and modified the rotor so they sit flush and its all good to go now!
I also had to modify the caliper mounting bracket to account for the larger disk brake. This meant welding up the lower bolt hole and drilling/ tapping a new one slightly to the side of the original one. Learned a lot through this front end swap! It was very fun.
Lastly I fabricated some wheel spacers, and now she is rolling! Just waiting on the steel braided custom length brake line and master cylinder and she’ll be all set up in the front!
I got the new enduro tires mounted, handle bars on, and got to roll the bike around finally. The image is starting to solidify in my head of the finished product.
Also, got the underside of the tank welded up. So I just need to weld the fuel tap and then seal it with some caswell and it is good to go!
Today I intend to get the front caliper properly mounted and mated with the wheel/ rotor. Been a bit of a bitch but it is coming together well.
So this took all day. I had to choose between painting the front black, and re-painting the rear black (because it looked faded) or stripping the rear to bare metal and match the front. The latter sounded easier…Maybe not the case! But there were several reasons for this. The bike doesn’t have much black on it, which is not something I do often, and I love that about it. I don’t want to go blackening up! The only black on this bike will be the frame. All else is raw metal except for the blue tank. Also, bare metal is more durable than paint! And easy to clean. So here we go.
I was just starting to clean it here. Once I cleaned it I painted it with some HARD FU**ING CORE paint stripper. And then scrubbed with a firm tooth brush. Then power washed it. Rinse repeat about 5 times and vuala!
There is a little shield for the final drive gear (you can see in the un-stripped picture) that I still have to paint and re-install. So it will look better when that’s done, and it is mounted so you won’t see that center part.
But it came out looking like new! Here they are together.
If you look close you can tell they aren’t matching spoke patterns. The one flat on the ground is the stock rear. The one leaning up with the front disk is from a Yamaha 600 Radian. It was the only front wheel I could find that had similar spoke pattern AND was the same dimensions as the rear wheel. Since I want matching tires. Now I just have to fab spacers and a caliper bracket and I’ll have a rolling and stopping machine!
So gas tank. What do I do about it? The stock one is just not going to fly, and the blue one you see in all the pics had to completely have the underside cut out in order to fit over the huge back bone of the Virago! Luckily…I found a solution.
Virago tank, meet nameless Yamaha donor tank.
Here is what’s left of the Virago original tank.
Now I know I’m not the first person to graft tanks together. But I guarantee I’m the first to graft THESE tanks together! Of course I still have lots of welding of sheet metal to do in order to seal and finish up the tank, but at least now it fits snugly on the bike using the original mounts! Today my goal is to get the wheel prepped and ready for tires. And hopefully finish the tank so I can caswell coat it soon.