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Diary of a custom TW 200 build

  1. #76
    Ginger Twin #2 AHAMAYs2's Avatar
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    Re: Diary of a custom TW 200 build


    This is an amazing project! It's a lot of fun to see what pieces you do next too!

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    What night is Burlington BIKE NIGHT?!?!?!?!?!

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  2. #77
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    The progress continues. Since I was doing away with the plastic side covers, I was going to have to make the airbox / battery holder better looking.

    This just doesn't look good without a side cover:



    One of the aesthetic things I liked about many of the Japanese TW customizations I've seen was "hollow" between the rear tire and seat.

    I got the air filter and crankcase breather taken care of with some cone filters, but still had to find a way to hold the battery. First I looked for the thinnest 12v battery I could find with similar specs to the stock battery. I ended up with an inexpensive battery used for fire exit lighting in buildings. I'm not planning on using the starter (kick start only) so I can get away with a small battery. Might move to capacitor-only in the future.

    Then I played with some cardboard to make a mock-up that would fit inside the frame. I transferred the mock-up to a sheet of metal from Lowes and then made the bends using a piece of wood clamped to the face of my workbench. Not scientific by any means.

    I am a IT guy by day, not a metal worker, so it's not perfect. Rivets hold the corners together.



    From there it went to the oven for a coating of powder and then onto the bike. I'm happy to report that the battery and wiring harness fit completely inside the box. Phew.



    And I like how it's barely visible from the side.





    Around this time, I also did "hitch pin mod". The original setup requires a wrench to free your seat from the frame, which could probably suck if you're in the woods somewhere without many tools.

    This "mod" makes getting your seat off-and-on as easy as pulling two hitch pins.

    You get 2 M6 x 1.00 x 40 bolts from your local hardware store and then cut the heads off. Then you mark where the pin passes through the frame mount and drill a hole big enough for the hitch pin that you also picked up at the hardware store.

    The result looks like this and works really well.



    Also put on some fat foot pegs.



    I then wired up this LED combination tail light, brake light, turn signal unit. I'm not really sold on the way it looks, but it's going to have to work.







    One last thing to do... get the gas tank finished!

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    Last edited by catamount; 08-25-10 at 12:32 PM.

  3. #78
    Lifer Chippertheripper's Avatar
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    Re: Diary of a custom TW 200 build

    totally righteous.

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    Cliff's Cycles KTM
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  4. #79
    Lifer Pittenger5's Avatar
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    Re: Diary of a custom TW 200 build

    God I wanna build one of these

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    Quote Originally Posted by Pookie View Post
    My favorite was you going through T2 with your eyes closed.

  5. #80
    Senior Member SVenpointsixtwo's Avatar
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    Re: Diary of a custom TW 200 build

    Awesome work so far! Definitely inspiration for my SR250 build...

    So you still haven't found a home for that mondo toolbox, huh?

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  6. #81
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build

    Awesome. Can't wait to see it done -- and see how it rides!

    --mark

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  7. #82
    is not wearing pants Point37's Avatar
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    Re: Diary of a custom TW 200 build

    i love this project...awesome work...keep the pictures coming

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  8. #83
    Spinner sandros's Avatar
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    Re: Diary of a custom TW 200 build

    Ok, I want to ride this thing SO badly. I wish I had the knowledge and time to do a project like this.

    Maybe this whole med school thing was a bad idea. Certainly hurts my bike addiction.

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  9. #84
    something witty here tsanterre's Avatar
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    Re: Diary of a custom TW 200 build

    looking good dude... got me wanting to take it for a rip!

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  10. #85
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    Thanks for the kind words guys.

    I'm having a hard time tying up loose ends on my TW project because I found photos of this sweet CB the other day.

    It was made by a small shop in Bali and built off of a '76 CB 100.



    Pretty much exactly the same bike as my $125 CB 125 that I've been waiting to restore.



    I was originally going to do cafe-racer type of build but what do you guys think of this? Love it or hate it? Anything you would change?











    BIKE BREAK DOWN:
    Rebuilt Honda 1976 CB100 Engine bored out to 180cc
    88mm aftermarket piston
    CDI added
    All engine bolts swapped for stainless steel
    4.5 inch chrome headlight from Japan

    Deus custom headlight bracket
    Smoked alloy Indicator lights from Japan
    Daytona speedo and bracket
    Easyriders ‘Early Tail-light’ from Japan
    
Ventura “BSA Style” Handlebars
    Kitaco handlebar controls
    Clip-on mirror

    Relocated ignition switch
    Custom battery housing
    Brown ‘British ribbed’ -style grips
    
Front suspension from Yamaha 225, chopped 5cm
    
32cm ‘Old style’ Yamaha rear suspension
    
Alloy rims: 18” rear, 18” front, with stainless spokes
    
Swallow tires, 120/80 18 front and same for rear.
    
Custom galvanized Tank
    
Custom seat upholstery

    
Rear frame section modified to accept seat and shortened 3 inches
    
Hidden horn and rectifier/regulator
    Front converted to ‘Flower disk brake’
    Re-wiring of whole bike
    Original rear hub swapped to Yamaha 225
    
Custom built Swing-arm made from steel tube.

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  11. #86
    Soul Rider Paul_E_D's Avatar
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    Re: Diary of a custom TW 200 build

    That is worthy of a replica, but by all means finish the TW.

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    Paul_E_D


  12. #87
    Lifer markbvt's Avatar
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    Re: Diary of a custom TW 200 build

    That CB is beautiful. Only thing I'd change that immediately comes to mind is the speedo -- I don't like it offset like that. I'd center it.

    Those tires look great on that bike, for some reason.

    --mark

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    My ride reports: Missile silos, Labrador, twisties, and more
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  13. #88
    Just Registered BMFR6's Avatar
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    Re: Diary of a custom TW 200 build

    hhmmm <wondering> could that be done with a CB200???? interesting

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  14. #89
    Lifer Chippertheripper's Avatar
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    Re: Diary of a custom TW 200 build

    love that cb too, but like dude said, finish that tee-dub.

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  15. #90
    is not wearing pants Point37's Avatar
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    Re: Diary of a custom TW 200 build

    i agree about the speedo and i'm not really a fan of the rear brake light location...maybe even look a bit better murdered without all the chrome in a flat paint color...either way that looks sweet!

    Quote Originally Posted by markbvt View Post
    That CB is beautiful. Only thing I'd change that immediately comes to mind is the speedo -- I don't like it offset like that. I'd center it.

    Those tires look great on that bike, for some reason.

    --mark

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  16. #91
    Posting Freak khuygie88's Avatar
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    Re: Diary of a custom TW 200 build

    Can't believe I'm just seeing this for the first time. Man, that thing looks awesome! Keep up the good work!

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  17. #92
    Posting Freak khuygie88's Avatar
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    Re: Diary of a custom TW 200 build

    Quote Originally Posted by catamount View Post

    Pretty much exactly the same bike as my $125 CB 125 that I've been waiting to restore.
    http://providence.craigslist.org/mcy/1916133227.html

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  18. #93
    HOOLIGANZ Icehole's Avatar
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    Re: Diary of a custom TW 200 build

    BRAVO!

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  19. #94
    Lifer catamount's Avatar
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    Re: Diary of a custom TW 200 build

    THE FINAL UPDATE!


    I'm done! In other words, my bike is operational and I've been riding it all about. To catch you up on the past couple of weeks...

    The tank color scheme had to go.



    I hit it with some aircraft paint remover in preparation for powder coat. This stuff makes crazy noises while it works.



    Back with a fresh powder coat covering. Notice the new chrome gas cap, which is off of an old vintage Yamaha.





    I found a lady on eBay who sells lots of gel decals. She had Yamaha decals but nothing in a yellow/black combination.

    She agreed to make me custom set for the low, low price of $10. Try getting that deal at your local dealership!



    Once I had the tank back on, it was off onto the roads for my first few miles.

    Before, right side:



    After, right side:



    Before, left side:



    After, left side:



    Maxxis 6006:



    The elusive TW in her natural habitat:



    Where she will live out the rest of her years:







    That's it! Thanks for reading about my build. It was a really fun project, and I learned more than I ever expected.

    Some things still need to be tweaked (headlight won't stay 'tight' after lots of bumps) and tuned (needle and jet need fiddling with after the air and exhaust mods) and I'll probably return back here to report on them as I find out what parts of my build worked, and what didn't.

    In the meantime, though, I'm off to ride this thing.

    -catamount

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    Last edited by catamount; 09-07-10 at 09:08 PM.

  20. #95
    Just Registered Doc's Avatar
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    Re: Diary of a custom TW 200 build

    Awesome build brother!

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  21. #96
    Lifer Expat's Avatar
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    Re: Diary of a custom TW 200 build

    [QUOTE=catamount;962586]Thanks for the kind words guys.

    I'm having a hard time tying up loose ends on my TW project because I found photos of this sweet CB the other day.

    It was made by a small shop in Bali and built off of a '76 CB 100.







    I was originally going to do cafe-racer type of build but what do you guys think of this? Love it or hate it? Anything you would change?



    I would add a front fender and a small piece of fiberglass around the rear of the seat to give it some shape and color

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  22. #97
    Senior Member gamorg02's Avatar
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    Re: Diary of a custom TW 200 build

    awesome work!

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  23. #98
    Lifer Pittenger5's Avatar
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    Re: Diary of a custom TW 200 build

    God I want one of those so bad

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    Zip Tie Alley #505

    Quote Originally Posted by Pookie View Post
    My favorite was you going through T2 with your eyes closed.

  24. #99
    Just Registered jcbell1007's Avatar
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    Re: Diary of a custom TW 200 build

    just saw your pics on FB and damn that thing looks awesome. great build justin. awesome work.

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  25. #100
    Lifer Chippertheripper's Avatar
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    Re: Diary of a custom TW 200 build

    So dope. I want.

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    Cliff's Cycles KTM
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    Close your eyes, look deep in your soul, step outside yourself and let your mind go.

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