Dave's XS500 project...

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Prof
Founder, Choppers Australia
Posts: 5625
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
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Dave's XS500 project...

Post by Prof » Fri Aug 04, 2017 7:32 pm

Dave sold his sporty a year ago and immediately regretted it and has been dropping in every week to accumulate parts for another project. He's paid all the main ones off and is ready to put some dough towards the build.

It has such a variety of parts we'd better call it Heinz! Frame is BSA swing arm converted to rigid with the back end of a rigid Harley frame. I picked it up at a swap meet years ago and it has been hanging in the shed awaiting its destiny. Dave is not into big motors and was happy to try an XS500 motor that has also been sitting in the workshop for a couple of years. The motor is sans carbies if anyone out there has some. Front end is a Harley narrow glide off a low rider judging by its length. Front wheel is a 73-77 sporty which has a distinctive star shaped rotor mount. I had a new 19" rim and stainless spokes set up on it, so it looks very tidy. I have a caliper and mount in my collection so the front end is together. Rear wheel is nicely chromed spoked big twin Harley. Dave picked a ribbed mustang tank (currently available) from my shelves and will go with a solo saddle...
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First step is setting up the BSA headstem to suit our Harley headstem and bearings. Knock out the old ball bearing cups...
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... and clean the steering head thoroughly...
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HD outer race is 4mm smaller in diameter than the BSA so we can make up a couple of bushes...
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Measure...
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Diagram of the basic bush, giving main dimensions. It will also have an internal lip for the race to pull up against...
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First bush made. The internal lip is filed out in two spots to allow a drift to be used to remove the races when they are worn...
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It is a tight fit in the BSA headstem, but is locked in with Loctite bearing mount...
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Once both bushes and HD races are fixed in, bearings are assembled and the triple trees installed. The BSA headstem is about 8mm shorter than the Harley, so I have opted to use a spacer between the bearing dust cover and top tree. I have chosen this approach as opposed to making the bushes longer in the steering head in case the extra leverage would loosen them. There is still sufficient machined surface on the headstem to support the top bearing...
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Spacer installed...
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Dave's new traditional chopper on it feet. Rear wheel is temporary until we get a tyre for his rear...
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Dave won't be back for a month, so this is probably as far as we will go for the time being. Next job will be mounting the motor and getting it aligned with the rear wheel.
Chopit'nrideit... Prof

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