Custom XS 650:

Hi Paul,

Love the XS650 site, tons of inspiration and direction. I've attached a couple of pics (before and during the transformation of my Winter project). The stock pipes had the baffles beaten (literally) out of them so the stock exhaust was replaced with a Mac 2 into 1 with chrome outlet pipe. They sound sweet and in combination with the K&N filters the bike takes off like a scalded cat. The seat was made by layering sheets of foam board insulation together to form the basic shape. After the form was covered with wax paper, 6 layers of fiberglass cloth were applied, then the hardended shell was lifted from the form. I made a seat pan from Baltic birch (marine grade) plywood which attaches the assembly to the crossbrace (behind the battery) with two 1/4-20 blind nuts. The tank is from a 1978 XS750 and holds almost two gallons more than the stock tank. Bullet turn signals, hub mount license plate bracket and cat's eye tail light were acquired on ebay. The paint job is ANSI  Safety Yellow Hammerite (in non-hammered finish), about 15 coats (sanded every 3 coats), final finish with 1600 wet/dry, rubbing compound, polishing compound then Merguiar's mirror glaze followed by automotive wax. Clubman bars (along withshorter cables for just about everything) were installed along with matte silver bar end mirrors. The seat is hand stitched (triple saddle stitch) leather which is attached with removable snaps (it makes access to the battery a breeze).  Padding is just enough to keep the vibration from numbing your ass on long rides. I've got tapered head bearings and bronze swingarm bushings on order. I hope to be riding this Spring which looks very realistic at the pace that I've taken since acquiring the bike in October (07).Again thanks for providing a great service to the riding public and inspiration to all of us XS650 enthusiasts in particular.

Take Care, Andy