Liking how the seat and tank are lining up. Fenders will be coming up next. The filler neck on the tank has been stripped in preparation of shortening.
This was the first version of the seat support that looked too high. Now on the scrap heap.
Brackets for the rear brake master cylinder and reservoir were made. These are the stock brake components from the original bike.
The rear tank hold-down bracket waiting to be welded on. I usually try to get all the brackets made while the bike is in the assembly area of the shop and then get them all welded on at once, reducing the time the bike is in the metal room potentially getting exposed to grinding dust.
Working on the template for the cover. The seat support and battery cover were made as a single unit, strengthening and stabilizing both.
Recycling old medical office folders for template making. A pile of schnitzles litters the base of the bike.
The primary is off the bike in preparation of the 29 tooth front sprocket and belt change.
Looking kind of naked without the primary drive.
The tank tunnel square opening that needed to be made to match the new frame.
A small arc of 1/8” steel was grafted in, welding only to the existing bracket, avoiding the body of the tank. The space above the tunnel opening is where a tab from the tank-top center console will attach.
There. That’s better on the tunnel, but the gas filler neck is pretty high and needs to be cut down.
I tried to strip the paint and heat the filler to see if it was perhaps silver soldered in like British bike tanks, but turns out they are welded in. In this before, the cap measures 2 3/8” tall.
The neck was cut off, weld carefully cleaned from inside the tube and around the filler insert, then silver brazed in.
1 1/2” inches now. With a pop-up screw cap, it will be even shorter.
Even with the stock gas cap it looks better!