xv1100 home convertion

[zakboy]

Hi all just a little insite into one of my home bike to trike convertions when i came up with this convertion it was aimed at those that would like to have a go at converting there own bikes to trikes on a low budget, so this is a very simple convertion but very effective that anyone could have a go at with a few pratical skills and a few power tools, in the UK quite a large number of trikes are home convertions and builds

in this instance the bike is a yamaha xv1100

[zakboy]

I started with a xv 1100 US import very clean with 26000 miles on the clock



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[zakboy]

Started by stirping down a reliant A stamped axle 3,23/1 ratio,gave it a good clean out checked for wear, and ground off all brackets from the outer axle tubes,then rebuilt


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[zakboy]

Next job was to get the bike into the shed and remove every thing i was not going to use.



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[zakboy]

I then needed to make up to bushes to screw in to the swingarm pivot points on the bike frame to protect the thread in case i wanted to return this to a bike at any point,then screwed the two bushes into the frame.



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[zakboy]

I had already decided that i was not going to use the bikes origanal swing arm in the project and would make my own swingarm,so cut out and put the bends in my tube witch was 34mm o/s/d with a 3.2 wall to make up the first part of the new swingarm


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[zakboy]

I then made up a bit of a jig to stop the tube rolling around why the two halves were tack welded and the rear brace was fitted, the rear bolting points were added and a bottom brace witch would suport the shocker mounting points.......but did not add a forward brace at this point


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[zakboy]

next it was time to sort the swingarm to bike mounting and pivot points for this i would use high grade M16 rose joints with a 2mm pitch thread with M16 HT bolts


I then used two M16 stud nuts to insert into the main rails of the swingarm for the rose joints to screw into, the swingarm would then be sloted at the ends of the main rails and the inserts would be welded in


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[zakboy]

Time to get the bike back out of the shed ready to face up the swingarm.


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[zakboy]

once the frame was faced up to the bike i needed to make up two spacers to fit between the pivot point on the bike frame and the rose joint on the new swingarm and used aluminium to make up the spacers


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[zakboy]

with the frame now bolted to the bike time to calculate the ride hight i wanted it to be at then add the mounting points for the shocks

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[zakboy]

Next job was to make a bracket to mount the 3/4 inch brake master cylinder but becuse the xv had a drum brake on the back when the brake foot pedal was depressed the atached brake rod pulled witch was the oposite to what i needed to operate the hydrolic master cylinder,so i had to make the bracket for the master cylinder with a pivot point on it to do what i needed the brake rod to do, this would then be welded to the front brace of the swingarm once the brace was was fitted

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[zakboy]

After mounting the front brace brake master cylinder for the rear brakes and hand brake mounting bracket and hand brake leaver the swingarm was then fully welded up and painted and refitted once again

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[zakboy]

next made up some simple mudguard brackets and added some small mudguards and fitted the wheels with new tyers


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[Memnoch451]

Those brits are pretty smart. I like it all so far.. let's see it with wheels and list info on mileage and how it handles. Pretty dang KOOL!

[zakboy]

after few more small jobs eg rear lights,forward marker light,hand brake cables and mudgaurds painted the rear end was again removed and returned to the shed to make a rear panel to cover the diff housing and axle tubes

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[zakboy]

The propshaft was made up by using one end of a reliant propshaft cut off to length, then made an insert to fit into the tube of the reliant prop the insert was drilled out center so the choped off bike shaft could then be inserted in to that

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[zakboy]

propshaft then welded up and painted

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[zakboy]

back to the diff axle cover made this up out of sheet steel

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[zakboy]

i then decided to carbon wrap the diff cover and the mudgaurds

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