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Diary of a custom TW 200 build

  1. #1
    Lifer catamount's Avatar
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    Cool Diary of a custom TW 200 build

    markbvt posted up a few weeks back about a 1994 TW 200 for sale in our area. I wasn't in the market for another bike but have heard only good things about these "Tee Dubs" so I thought I'd check it out. It was pretty cheap... $600.

    I ended up snapping it up and driving it around for the past month or so. I love this bike!

    The day I bought the bike:



    However, I also have a laundry list of things I'd like to change. The bike hit 10,000 miles on the nose and I decided that 10k miles is a good time for a complete rebuild.

    • Replace street tires with knobby tires
    • Replace bent handlebars with new upgraded aluminum bars
    • Replace boxy headlight with single round or double round
    • Get rid of plastics and grind down their mounting posts
    • Remove and grind down passenger pegs
    • Upgrade to a larger tank (the XT350 tank is a direct fit)
    • Recover the red seat or find a used black seat
    • Repaint the frame and swingarm black


    I'm not going to go as crazy as some of these examples, but here are some custom TW 200s that I'm taking ideas from:









    So the other night I fired up my air ratchet and started tearing this thing apart. As of last night, I'm down to the bare frame.

    I'm going to keep this post updated with the build. Suggestions and comments are welcome!

    Before:







    Starting to strip the bike down:



    My new rubber came in!

    Stock rear knobby (180/80-14) and Maxxis 6006 (130/80-18) front.







    Air tools and Sam Adams help keep the ball rolling:



    In-progress in my "other bay"... exhaust valve re-shim on Speed Triple:



    The only running bike... 1978 CB 125:



    Okay, now the engine is out. Easily lifted by one guy. Nice.

    The jug looks nearly new but I'm going to paint the crank case black and replace the japanese-style bolts with hex head bolts.



    Getting close!



    Carnage. Some of these parts will go back on the bike, many will go on eBay.





    Stay tuned for more updates as work continues...

    April 18th, 2010

    Mark came over and helped me mount up my knobbies. Thanks Mark!

    That is a Maxxis 6006 front and a TW34 rear.




    April 20th, 2010

    I'm going minimal on this bike... no plastics. In order to prep the frame, I'm grinding down the plastic mounting posts and tabs for the airbox.






    April 23rd, 2010

    Home-style sandblasting. A few hours in the driveway with a 40 pound sandblaster, a 100 pound bag of "black beauty" and a compressor working overtime.



    It is seriously amazing what air pressure can do for you.





    Frame and swingarm ready for paint!



    April 25th, 2010

    Back from the powdercoater! I think he did an excellent job. Bob at Vermont Powdercoating did the work and really gave me a great deal.





    May 3rd, 2010

    The engine was originally gray in color. It was also heavily scratched. I decided to clean it up and use some black enamel engine paint on it.



    May 6th, 2010

    Someone on the TW200 forums found that the shock from a Yamaha Blaster is a direct fit for the TW, but 2 inches taller.

    This will really jack the rear end of the bike up once mounted. The only problem was that the bushing was far too lose. I had a machinist friend bore me the perfect bushing and press it in for me.

    The shock was $8 on eBay and the machining work cost me a case of Miller High Life (hey, his choice!).



    Current status:



    Stay tuned for sprockets, chain and wheels!

    No more dates as they're all blending together on me...

    Had to get rid of all of those nasty stripped JIS head bolts. Ordered up a set of SS hex head bolts. Of course a few were missing.

    So much bling! I'm ballin.



    Sprocket time. I'm a fan of having more teeth to spread the load. Upping from the stock 14t to a 15t up front.



    The rear goes from stock 50t to a new 55t. The overall gear difference is slightly lower than stock.



    I've heard good things about this vinyl spray so I'll give a shot. Original tired red seat...



    Looks new about an hour later:



    The original steering bearings were loose ball bearings and the feel was notchy. I decided to upgrade to some tapered bearings. Packed 'em with grease and punched 'em on.

    Also decided to powder coat the triple trees. They were looking a little ragged, so why not?



    Now that I've got trees, I can mount my forks and bars!



    Still so much more to go, but any progress is good progress.

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    Last edited by catamount; 08-09-10 at 03:06 PM.

  2. #2
    Soul Rider Paul_E_D's Avatar
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    Re: Diary of a custom TW 200 build

    Holy shit, that first Bobber TW is siiick! and I never thought I'd say that. These bikes are popular with the RV crowd...

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    Paul_E_D


  3. #3
    Lifer obsolete's Avatar
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    Re: Diary of a custom TW 200 build

    That is gonna be a cool bike. Those customs are pretty awesome.

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  4. #4
    Your Father csmutty's Avatar
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    Re: Diary of a custom TW 200 build

    I love TW200s. If I have the money some day I will get one. I can't wait to see the finished project.

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  5. #5
    Lifer Chippertheripper's Avatar
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    Re: Diary of a custom TW 200 build

    I need one of those.

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  6. #6
    LRRS EX #99 Kitt's Avatar
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    Re: Diary of a custom TW 200 build

    dude, i love TW's... sweet project, I'm watching

    only thing that sucks is they are gutless... and if that's the one I called about, he had no paperwork for it.

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  7. #7
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by Kitt View Post
    if that's the one I called about, he had no paperwork for it.
    Yep, no paperwork. In VT you don't need paperwork for anything more than 10 years old (or something like that).

    I'm good to go.

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  8. #8
    Just Registered Doc's Avatar
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    Re: Diary of a custom TW 200 build

    I like the Flat Tracker.

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  9. #9
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build



    Let me know if you need a hand with anything.

    I wonder how hard it would be to stick an XT350 engine in there...

    --mark

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    Last edited by markbvt; 04-14-10 at 11:16 AM.
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  10. #10
    Senior Member FTMS's Avatar
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    Re: Diary of a custom TW 200 build

    Those are nice machines. I have a BW200 that I love going through the woods with.

    I would look into one of the newer TTR motors since there is a bunch of aftermarket stuff for those motors.

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  11. #11
    Ginger Twin #2 AHAMAYs2's Avatar
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    Re: Diary of a custom TW 200 build

    That's a sick project! Also i have ADD so i saw the part that said you were modifying your bike and i scrolled down and thought the first custom was your rebuilt one Then i read on and discovered the truth....

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  12. #12
    Custom User Title Dichotomous's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by AHAMAYs2 View Post
    That's a sick project! Also i have ADD so i saw the part that said you were modifying your bike and i scrolled down and thought the first custom was your rebuilt one Then i read on and discovered the truth....
    thats not ADD, thats reading comprehension. ADD is more in the likes of: "I saw the part that said you were modifiying your bike and I scrolled down and started thinking about butterflies that land on flowers are red and pretty which is very nice....."

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    theres just something about a blue bike

  13. #13
    Ginger Twin #2 AHAMAYs2's Avatar
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    Re: Diary of a custom TW 200 build

    he he he

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  14. #14
    TWINS! xrocket21's Avatar
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    Re: Diary of a custom TW 200 build

    awesome! I love the look!!!!!!!

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  15. #15
    Posting Freak yesterdayze's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by AHAMAYs2 View Post
    he he he
    nah, he's right he does have AD... hey what is on your bandanna anyways parker?

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  16. #16
    Ginger Twin #2 AHAMAYs2's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by yesterdayze View Post
    nah, he's right he does have AD... hey what is on your bandanna anyways parker?

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  17. #17
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by yesterdayze View Post
    nah, he's right he does have AD... hey what is on your bandanna anyways parker?
    He has a bandana?

    --mark

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  18. #18
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    Get out of my thread, douchebags!


    But since you're here...



    Would you (a) powdercoat the frame for $250 + no labor + more durable finish or (b) rattlecan the frame for $50 + 6 hours labor sanding, prepping, etc?

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  19. #19
    Posting Freak 6 Fingered Man's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by catamount View Post
    Get out of my thread, douchebags!


    But since you're here...



    Would you (a) powdercoat the frame for $250 + no labor + more durable finish or (b) rattlecan the frame for $50 + 6 hours labor sanding, prepping, etc?
    Rattlecan......

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  20. #20
    Ginger Twin #2 AHAMAYs2's Avatar
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    Re: Diary of a custom TW 200 build

    how much free time do you have on your hands? Could you easily afford the powder coating with all the other mods and fixes that your doing to the bike?

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  21. #21
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by AHAMAYs2 View Post
    how much free time do you have on your hands? Could you easily afford the powder coating with all the other mods and fixes that your doing to the bike?
    I can afford the $250 paint job but it would pain me to spend 1/3 of the bike's value on paint for the stupid frame.

    I think it might be rattlecan! Or at least spray gun for my compressor and DIY paint booth.

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  22. #22
    Braap Baggey22's Avatar
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    Re: Diary of a custom TW 200 build

    Go with the spray gun for your compressor and DIY paint booth.

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  23. #23
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by catamount View Post
    Would you (a) powdercoat the frame for $250 + no labor + more durable finish or (b) rattlecan the frame for $50 + 6 hours labor sanding, prepping, etc?
    Neither. Sandblast frame (I can help with that if you don't have the resources), weld anything that needs it, do any bondo work you might want, then HVLP spray with two-part epoxy primer. Let cure, HVLP spray with paint or clearcoat.

    The epoxy primer is about as durable as powdercoat if you spray on multiple coats.

    --mark

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  24. #24
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by markbvt View Post
    Neither. Sandblast frame (I can help with that if you don't have the resources)
    I do need a sandblast resource! I called a guy in Milton called "Finish Solutions" but no reply yet.

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  25. #25
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build

    Check your PMs.

    --mark

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