Finished this project a while back. Thought I'd share

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I Have been riding this beast everyday since Feb. I love the looks I get.
I am curious to hear what XJ enthusiats have to say about it. I did 99% of the work myself. The only thing I didn't do was bend the rear shock hoop (I don't have a tube bender (YET)).

 

Looks amazing to me! I love the style! Tell me about the exhaust (I'm new at this)

 

I built the mufflers from scratch. Started with some left over 4" steel exhaust pipe from my friend's powerstroke. Squeezed it into an oval shape and machined some 3/4" aluminum end caps. Inside is some perforated stainless muffler core tubing (I got from Cruiser Customizing) wrapped in dirt bike muffler packing. the turn downs are 45 deg 1-1/4" copper elbows from home depot. I used the stock pipes and hacked them into a 4-2 setup then used exhaust adapters (don't remember the size) from autozone as collectors and just hammered them into the shape I wanted. The wrap is mostly just there to hide the ugly welds.

 

I built the mufflers from scratch. Started with some left over 4" steel exhaust pipe from my friend's powerstroke. Squeezed it into an oval shape and machined some 3/4" aluminum end caps. Inside is some perforated stainless muffler core tubing (I got from Cruiser Customizing) wrapped in dirt bike muffler packing. the turn downs are 45 deg 1-1/4" copper elbows from home depot. I used the stock pipes and hacked them into a 4-2 setup then used exhaust adapters (don't remember the size) from autozone as collectors and just hammered them into the shape I wanted. The wrap is mostly just there to hide the ugly welds.

 

Very nice bike mate!
I like your rear mono shock mod! ... How big is the diameter on the hoop?

kinen1

 

and the rear fender is looking damn sweet!!!!

 

So question I have what size jets did you go for for the re jetting for that carb / exhaust setup?

 

Do you have a couple side-view shots to show off the shock and frame mods??
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Color scheme reminds me a bit of the "Painter-D" bike !!

 

x2.

 

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This was its first re-incarnation.

As for the jetting, its stock and actually runs really well. Admittedly, I really ought to change the pilots, its hard to start and idles weird but its not bad enough for me to care.

 

It still has what appear to be original 30-year old brake lines. If so, it's not finished.

 

Yeah, I agree. I've got some custom braided stainless one on there now.

 

good lord that's hot!

 

where did u get those clip on hand grips?

 

Sorry all,
I've been away for awhile. (Military deployment)

So, the brake lines have been replaced with some custom built ones from a local hydraulic shop. I went with two independent line from the master cylinder.

The rear hoop is about 6 inches in diameter, that's the only piece I didn't do myself. Local hot-rod shop bent it for me from a template I made.

The rear fender is a front fender from a Suzuki M109

The clip-ons are homemade

The rear shock/spring assembly is from a '06 ZX6-R. (got it for $80 on Craigslist)

 

1st, Thank You for your service. Like the mods, something different for a change.

 

Yes, thank you for your service to our country.

And welcome home, both physically and in the cyber world.