Project XL185/CG250 swap - Page 27

XLsior · 03-06-2023, 01:23 AM

Aliexpress cheapest 17t front sprocket I found,

$7 AUD shipped.

looks solid enough where it matters.

definite /doubt on the 8.8* tensile bolts...but they only hold the retainer clip.

won't use them but put them in the spares tool kit.

XLsior · 03-06-2023, 10:16 PM

Ebay Pannier rack arrived today.

The is no XL185 option, so I intend to modify an existing product to suit application.

Each side costs about $35aud...I could not fabricate something from scratch cheaper or look better.

Other model bikes are available ranging in price, size and mounting positions.

the DRZ was the cheapest I could find on Ebay.

The pannier hoops are about perfect dimensions...

the mounting bracketry is asymmetrical, But most of this will be cut up and adjusted.

I thought about mounting off the shock mounts, but decided on making dedicated lower hard mounts welded lower on the frame.

XLsior · 03-14-2023, 10:29 PM

After about 3 passes of body filler and sanding with 120grit I got about as far as I could before hitting a negative return point.

Triple checked again for full steering lock clearances...tolerances a tight but enough...

Did a full pass sand over with 240grit and wiped down with isoprpyl. I don't have any wax/grease remover.

Had a little spray filler/primer which i spot sprayed in some areas but basically applied the first light coat of etch primer...

will let that cure and look for any areas requiring more blend and finish sanding....

then a 400grit pass over and second coat of primer.

**JerryHawk250** · 03-15-2023, 08:34 AM

Nice job on tank.

I enjoy reading your thread and watching the progress.

XLsior · 03-15-2023, 03:51 PM

Thanks Jerry,

the first coat of primer has made any filler mistakes pop.

So...likely a 4th pass of filler yet to come.

XLsior · 03-17-2023, 08:58 PM

a coat of primer will show up any imperfections...

Which lead to another round of body filler and sanding.

Obviously perfect dent symmetry is no easy feat with rudimentary tools..

So I'm settling for close enough, though trying to give the color and clear coat the best chance of smooth coverage.

after this 4th pass cures I will got over with 600grit and hopefully then the color coat is good to go weather permitting.

XLsior · 03-19-2023, 01:22 AM

Regency Red Pearl

2 light 1 heavy coat ish...

will give it a couple of days in the spare room to cure...

then will think about any decals/decorations before clear coat...

So back to the pannier/racks and frame mounts...

Need to get that done because the can of 2k clear coat is only good for 8hrs recommended.

So few other bits to do other than the fuel tank...

XLsior · 03-19-2023, 11:10 PM

Searching for motorcycle pannier/saddle bags came up with with numerous results which for the prices seemed to range from ok to ridiculous with all but a bit much for my liking.

So I searched pannier bags and came across bicycle options all being much cheaper....

Figured I was already modifying racks It shouldn't be to hard to modify bags...

Found this type for under $20aud shipped...that's $10 a side, not bad at all. Can fit a 5lt jug with room to spare...

has a weatherproof lining and overflap....so some rain protection.

Had straps in about the right places...

Came in Red/Black/Silver...so matches my bike scheme nicely.

Basically just cut down the middle and BAM now they're rack ready.

XLsior · 03-22-2023, 02:34 AM

Wet Week...No tank paint for now...

Made room in the garage and went to work fixing fixings and mounting mounts...

Using M8 and M10 couplers, Threaded rod was used for alignment. Gound down a contour to get the M8 coupler more flush with the round frame..

XLsior · 03-26-2023, 02:43 AM

More work on the pannier racks...

Tidied up and refreshed the paint on the frame...

With the M8 and M10 couplers welded in position, Upcycled some parts of the racks that were cut off to use as a mount plate and support struts.

A section of threaded rod cut to length for each side holds the upper support.

It allows for adjustment and easier removal opposed to a hard mount welded to the rear rack....

Racks are painted in duplicolor bedliner...

I used foil as paint and weld shielding while working in the frame...

Starting to put it back together now...

Also I have clear coated the tank...but I am letting it cure before any update.

XLsior · 03-29-2023, 02:55 AM

So the the side project of making an XL350 fit has come close to completion.

The final red and clear coat came out alright, its not showroom perfect by any stretch, Some mild orange peel and the odd dust spec but no runs or fisheyes...

However it does look better than it did before.

I also decided to free hand some doodle designs with a silver paint pen...
To help break up any imperfections in the paint coats...

Made it a bit more custom...I also added a personal note/phrase as a memento.

I am waiting on tank rubber knee pads before adding the Honda Decals...

Considered clear coating over the decals but opted against it as its easier to replace decals then failed clear coat...

XLsior · 03-29-2023, 03:06 AM

Custom Pannier racks also completed...

3 points of support...

Also added 2x m10 nuts to uses as lock nuts, which really solidify the whole frame structure.

Solid enough, Clears the shocks and most of the weight is forward of the rear wheel hub...

As for the 17t front sprocket, it went on fine with enough clearance...I did feel a small snag so opted to dremel away some minor case protrusions for a little more wiggle room.

Finally got the flap disk and shaved the head fins a little to clear the petcock on the xl350 tank....

XLsior · 03-30-2023, 11:13 PM

Figured I'd make a way to attach the pannier bags to the racks in a more optimal way than zip ties and straps...

I decided on making insert side/base support panels.

Made a cardboard mock up using the bag and base dimensions and transferred the stencil to an old busted wheelie bin/Trash can made from HDPE about 5mm thick (had it lying around for such a reason)

Cut out the panels (mirrored for either side) and got the heat gun to form a bend at the base....Shaped to fit and sanded down any sharp edges/corners.

Then I got some M8 nutserts and fixed them to the racks...

mark out the holes on the panels at the desired level placement...

then put the panels inside the bags and pushed a screwdriver using the holes as guides and through the side of the bag...

M8 bolts through and bolted up...wont budge now...

Now the bags are bolt on/off, with better strength and less likely to spill the beans if the base rips...

XLsior · 03-31-2023, 02:14 AM

Retro Rubber Knee pads arrived...

Decal day...

I had these custom tank stickers made way back at the start of the project, but for some reason i just didn't want to stick them to the original tank after repainting it...

The more the XL350 tank stays on the frame the more in proportion it feels which I wasn't sure would happen when I first tried to fit it...

But now that its all done up it just feels right on the bike.....

I tried to get the decal level with the ground and more center than factory...

Getting the other side to match is the hard part but I'm in the close enough camp...

I Suppose that's the final Cherry on top of the project...

Other than CG300 cylinder kit it's safe to say the project is "Complete" as envisioned though there was some scope creep...

XLsior · 04-02-2023, 10:25 PM

Establishing tank volume and reserve capacity.

With the petcock set to full I used a measuring cup to fill the the tank up to the point the reserve spills over, Which is approximately 1.2lt.
I then filled up the tank using a 2 full* 5lt jerry cans + 1l making the expected 11l /2.91gal specification. Seems the dents and tank liner coat didn't do much to tank capacity...which is great.

Original XL185 was only 7l /1.85gal

Will set the trip to 0 and record the distance traveled till the next fill stop to establish a MPG/KMPL.

I will stick to "get her done, 91" ron fuel from now on.

03-06-2023, 01:23 AM	#391
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Cheap17t Aliexpress cheapest 17t front sprocket I found, $7 AUD shipped. looks solid enough where it matters. definite /doubt on the 8.8* tensile bolts...but they only hold the retainer clip. won't use them but put them in the spares tool kit. Attached Thumbnails
	0

03-06-2023, 10:16 PM	#392
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Ebay DRZ400 Pannier Rack Ebay Pannier rack arrived today. The is no XL185 option, so I intend to modify an existing product to suit application. Each side costs about $35aud...I could not fabricate something from scratch cheaper or look better. Other model bikes are available ranging in price, size and mounting positions. the DRZ was the cheapest I could find on Ebay. The pannier hoops are about perfect dimensions... the mounting bracketry is asymmetrical, But most of this will be cut up and adjusted. I thought about mounting off the shock mounts, but decided on making dedicated lower hard mounts welded lower on the frame. Attached Thumbnails Last edited by XLsior; 03-07-2023 at 12:10 AM.
	1

03-14-2023, 10:29 PM	#393
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Tank Shaping up After about 3 passes of body filler and sanding with 120grit I got about as far as I could before hitting a negative return point. Triple checked again for full steering lock clearances...tolerances a tight but enough... Did a full pass sand over with 240grit and wiped down with isoprpyl. I don't have any wax/grease remover. Had a little spray filler/primer which i spot sprayed in some areas but basically applied the first light coat of etch primer... will let that cure and look for any areas requiring more blend and finish sanding.... then a 400grit pass over and second coat of primer. Attached Thumbnails
	2

03-15-2023, 08:34 AM	#394
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,568	Nice job on tank. I enjoy reading your thread and watching the progress. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	0

03-17-2023, 08:58 PM	#396
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	4th pass 400grit and primer a coat of primer will show up any imperfections... Which lead to another round of body filler and sanding. Obviously perfect dent symmetry is no easy feat with rudimentary tools.. So I'm settling for close enough, though trying to give the color and clear coat the best chance of smooth coverage. after this 4th pass cures I will got over with 600grit and hopefully then the color coat is good to go weather permitting. Attached Thumbnails
	1

03-15-2023, 03:51 PM	#395
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Thanks Jerry, the first coat of primer has made any filler mistakes pop. So...likely a 4th pass of filler yet to come.
	1

03-19-2023, 01:22 AM	#397
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Weather Permitting Regency Red Pearl 2 light 1 heavy coat ish... will give it a couple of days in the spare room to cure... then will think about any decals/decorations before clear coat... So back to the pannier/racks and frame mounts... Need to get that done because the can of 2k clear coat is only good for 8hrs recommended. So few other bits to do other than the fuel tank... Attached Thumbnails
	1

03-19-2023, 11:10 PM	#398
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Pannier Bags Searching for motorcycle pannier/saddle bags came up with with numerous results which for the prices seemed to range from ok to ridiculous with all but a bit much for my liking. So I searched pannier bags and came across bicycle options all being much cheaper.... Figured I was already modifying racks It shouldn't be to hard to modify bags... Found this type for under $20aud shipped...that's $10 a side, not bad at all. Can fit a 5lt jug with room to spare... has a weatherproof lining and overflap....so some rain protection. Had straps in about the right places... Came in Red/Black/Silver...so matches my bike scheme nicely. Basically just cut down the middle and BAM now they're rack ready. Attached Thumbnails
	0

03-22-2023, 02:34 AM	#399
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Weather not Permitting Wet Week...No tank paint for now... Made room in the garage and went to work fixing fixings and mounting mounts... Using M8 and M10 couplers, Threaded rod was used for alignment. Gound down a contour to get the M8 coupler more flush with the round frame.. Attached Thumbnails
	2

03-26-2023, 02:43 AM	#400
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Pannier Rack More work on the pannier racks... Tidied up and refreshed the paint on the frame... With the M8 and M10 couplers welded in position, Upcycled some parts of the racks that were cut off to use as a mount plate and support struts. A section of threaded rod cut to length for each side holds the upper support. It allows for adjustment and easier removal opposed to a hard mount welded to the rear rack.... Racks are painted in duplicolor bedliner... I used foil as paint and weld shielding while working in the frame... Starting to put it back together now... Also I have clear coated the tank...but I am letting it cure before any update. Attached Thumbnails
	3

03-29-2023, 02:55 AM	#401
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	XL350 Tank Mod So the the side project of making an XL350 fit has come close to completion. The final red and clear coat came out alright, its not showroom perfect by any stretch, Some mild orange peel and the odd dust spec but no runs or fisheyes... However it does look better than it did before. I also decided to free hand some doodle designs with a silver paint pen... To help break up any imperfections in the paint coats... Made it a bit more custom...I also added a personal note/phrase as a memento. I am waiting on tank rubber knee pads before adding the Honda Decals... Considered clear coating over the decals but opted against it as its easier to replace decals then failed clear coat... Attached Thumbnails
	1

03-29-2023, 03:06 AM	#402
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Rack Done and 17t sprocket. Custom Pannier racks also completed... 3 points of support... Also added 2x m10 nuts to uses as lock nuts, which really solidify the whole frame structure. Solid enough, Clears the shocks and most of the weight is forward of the rear wheel hub... As for the 17t front sprocket, it went on fine with enough clearance...I did feel a small snag so opted to dremel away some minor case protrusions for a little more wiggle room. Finally got the flap disk and shaved the head fins a little to clear the petcock on the xl350 tank.... Attached Thumbnails Last edited by XLsior; 03-29-2023 at 08:38 AM.
	2

03-30-2023, 11:13 PM	#403
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Pannier Bag Insert Support Figured I'd make a way to attach the pannier bags to the racks in a more optimal way than zip ties and straps... I decided on making insert side/base support panels. Made a cardboard mock up using the bag and base dimensions and transferred the stencil to an old busted wheelie bin/Trash can made from HDPE about 5mm thick (had it lying around for such a reason) Cut out the panels (mirrored for either side) and got the heat gun to form a bend at the base....Shaped to fit and sanded down any sharp edges/corners. Then I got some M8 nutserts and fixed them to the racks... mark out the holes on the panels at the desired level placement... then put the panels inside the bags and pushed a screwdriver using the holes as guides and through the side of the bag... M8 bolts through and bolted up...wont budge now... Now the bags are bolt on/off, with better strength and less likely to spill the beans if the base rips... Attached Thumbnails Last edited by XLsior; 03-31-2023 at 09:09 PM.
	2

03-31-2023, 02:14 AM	#404
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Decals and Knee Pads Retro Rubber Knee pads arrived... Decal day... I had these custom tank stickers made way back at the start of the project, but for some reason i just didn't want to stick them to the original tank after repainting it... The more the XL350 tank stays on the frame the more in proportion it feels which I wasn't sure would happen when I first tried to fit it... But now that its all done up it just feels right on the bike..... I tried to get the decal level with the ground and more center than factory... Getting the other side to match is the hard part but I'm in the close enough camp... I Suppose that's the final Cherry on top of the project... Other than CG300 cylinder kit it's safe to say the project is "Complete" as envisioned though there was some scope creep... Attached Thumbnails Last edited by XLsior; 03-31-2023 at 05:52 AM.
	4

04-02-2023, 10:25 PM	#405
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,296	Establishing tank volume and reserve capacity. With the petcock set to full I used a measuring cup to fill the the tank up to the point the reserve spills over, Which is approximately 1.2lt. I then filled up the tank using a 2 full* 5lt jerry cans + 1l making the expected 11l /2.91gal specification. Seems the dents and tank liner coat didn't do much to tank capacity...which is great. Original XL185 was only 7l /1.85gal Will set the trip to 0 and record the distance traveled till the next fill stop to establish a MPG/KMPL. I will stick to "get her done, 91" ron fuel from now on.
	1