….so then I met Justin and Gary outside the public toilets and happened to comment “this doesn’t look very much like a cottage? are you sure this is right place…..ok lets go in”…ah shit, wrong blog!

Welcome back people, I have in fact crossed the point of no return now with my motorbike project. The past week I have had a different kind of date with my grinder. I have been hacking my motorbike to bits, because shearing every bolt and misplacing all the important parts wasn’t a bad enough ordeal for the poor Yamaha…This week had me doing the first few bits of work that were outwith my comfort zone…

Delugging the frame

This is the process of cleaning up the frame to get rid of all the lugs and mounting points that will be surplus to requirements once I start to reassemble the bike. With the bike stripped down to a bare frame, it was quite obvious to see the mounting points which were due to be chopped…see below pictures:

Frame showing lugs that need to be removed
Artists impression of what needs to be removed

I have done some research on what I want my bike to look like as previously outlined here. The XS750 can be opened up nicely from the original design by removing the side covers and relocating the battery to another point on the bike. Opening up the bike allows  the carbs to be exposed and this is what drew me to going with this type of design…plus the mini cone filters will be a homage to my boy racer days where I had a big dirty K&N filter that gave my 1.25l fiesta a meaty growl…unlike the car, the bike might actually have the speed to back up the noise!

Neat exposed area under the seat….need to figure out where to put the battery though!

First things first, the tools. I had bought a grinder last year for another project but it hadn’t really been used much…luckily angle grinders don’t tend to be used much for home DIY, so it wasn’t on permanent loan to anyone :D….time to put it to use!

Before I could start, I had to get a variety of disc’s in order to carry out the work needed on the bike. In the end I used 4 types of disc’s

  • Cutting discs – Does what it says on the tin, used to cut through the metal taking the bulk of the material off – Thin wheel
  • Grinding discs – Used to tidy up and remove the excess material left from the initial cut  – Thicker wheel
  • Sanding disc – Flaps of sand paper used to clean off paint and smooth over the grinding disc marks
  • Wire wheel – Wire brush type attachment for the grinder, good at removing any surface corrosion & old paint

Again, get yourself a pair of goggles, gloves and ear protectors. I made the mistake of not wearing ear protectors this week for the first session and my hearing was definitely numbed….Also, these things operate at up to 10,000 rpm, do you really want some shrapnel heading towards your eyes at that speed? I’m as blind as a mole already and don’t need anything making it worse!

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Now onto the fun part….Fubaring the bike! I followed a simple process – choose/chop/grind/sand

Choose a part you want to remove – in this case one of those awful looking lugs:

Victim 1 – held on with a long weld 

Fit the cutting disc and go to town:

You will be left with a part that looks like the following, which will need the grinding wheel to remove the excess. Be gentle with the grinding wheel, it can take a lot of material off if you are too harsh….it’s easier to go slow and take more off, than to try and replace the metal you have turned into 1001 shavings on the garage floor…

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I actually only used the sanding wheel at a later date to clean up some rusted parts on the frame and to expose a small hole which will need welded up (to be explained in the next blog post).

After an afternoon with the angle grinder you are left with a frame that has been tidied up a bit:


Frame, ready for its next butchering

The next post will cover the removal of the rear end of the frame – in order to get that cafe racer/brat bike look, that lumpy rear end needs some work…and some sleeker metal welded into its place.

To be continued…