Once the bike was in the shop for two days I had to hear "Who the hell welded this up?" I got tired of saying "me," so Mike and I went over all the things that I knew needed to get fixed and welded the right way. At the same time Jason started building a custom seat pan, handlebars that were straight, and cutting and re-welding the exhaust pipe. When I mocked up the pipes I was able to get them to fit and flow with the lines of the frame, but they were a little off due to me making them a two-into-one pipe using a MIG welder. So there was still a lot of work ahead to get the bike ready for powdercoating and paint. I dropped off the roller (it did roll) at the shop in its raw, very rough state. Almost everything needed to be permanently welded, and I still needed a seat pan made. Jason and Mike got started by taking all the measurements for where the seat pan would sit on the frame, and how the exhaust would mount, as well as making a set of handlebars that would hold up.
Next, Jason removed the bars...
Next, Jason removed the bars that I had made, took some measurements, then tossed my set in the scrap pile and started to make another (true-working) set. My welds were not so good.
Jason's welds: Here you can...
Jason's welds: Here you can see what you would rather see on a bike.
I wanted to keep the bars...
I wanted to keep the bars tall, so 16-inch bars were made. I can still go with a short or tall set of risers to get the bars at the right height.
Jason also moved the petcock...
Jason also moved the petcock bung to the rear to the gas tank. Before it was too far forward, and the petcock would have hit the top of the motor.
Next was the seat pan. Jason...
Next was the seat pan. Jason started by tracing out the frame lines onto a piece of paper and marking where the tubes and oil bag would fit. This gave him an idea of how wide and long the pan needed to be.
With a sheet of 14-gauge flat...
With a sheet of 14-gauge flat stock, Jason trimmed out a piece and cut out the rough shape.