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  #1  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default My 99 X1 ive been building/modifying over the past few years

figured i would start a build post-

Ive been working on this bike since I purchased it back in 2008. I was really in search of a XB but always loved the X1. The bike has gone through a few phases over the last couple years but hopefully its to the point of just about finished.

some of my build can be found here-

http://www.customfighters.com/forums...ighlight=buell


Im pretty bad at taking pics along the way of the build and mods but ill post some up that i have.

here is the bike (basically stock) the day I bought it June 12 2008 ( 2 days before my first child was born)





and here are the latest pictures at the end of 2013






many new parts have been designed and made over the winter and not seen in the latest pics above.
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  #2  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default

Here is everything that I have done to the bike- Everything I have labeled as MC Moto-Worx I have designed in solidworks and machined myself. Most parts were first built on a Rapid Prototype machine/ 3D printed to verify fitment and function before machining.

--------Body/Frame/Wheels--------
-Metallic Ocean Blue paint
-Custom cut tank "BUELL" decals under clearcoat
-Carbon fiber tank inserts
-Custom HT Moto factory reworked seat
-MC Moto-Worx fabricated Chrome-moly tail (powdercoated)
-MC Moto-Worx fabricated under seat electronics tray (powdercoated)
-MC Moto-Worx fabricated Undertail
-MotoGadget Miniscope Speedo
-MC Moto-Worx fabricated billet mount for MotoGadget Miniscope speedo (powdercoated)
-B2R billet pegs (anodized black)
-MC Moto-Worx fabricated billet marker plate mount (anodized black)
-MC Moto-Worx fabricated billet heal guards (powdercoated)
-Frame (powdercoated)
-Rethal Fatbars (powdercoated)
-Rizoma Billet handgrips
-Bar-end Mirrors
-PreEng risers (black anodized)
-CRG brake/clutch levers
-Custom length Motion Pro clutch cable
-MC Moto-Worx fabricated billet Penske reservoir frame clamps (anodized black)
-All wiring hidden in handlebars
-XB wheels (powdercoatd)
-MC Moto-Worx fabricated rear wheel XB wheel spacers/reducers
-Orange wheel stripes
-X1 wingarm - shaved - machined slot for hidden rear caliper (powdercoated)
-MC Moto-Worx fabricated rear sliders/axle covers (powdercoated)
-06+ XB rear hugger (modified)
-XB front fender
-XB front axle
-Storz Steering damper
-MC Moto-Worx fabricated billet shifter (black anodized)
-MC Moto-Worx fabricated billet brake lever (black anodized)
-MC Moto-Worx fabricated billet rearsets (powdercoated)
--------Lighting--------
-V-rod Headlight (painted bucket)
-MC Moto-Worx fabricated billet headlight brackets (powdercoated)
-MC Moto-Worx fabricated billet indicator light housing with LED lights
-Dual High/lowbeam Mod
-Marker plate frame with LED marker lights
-MC Moto-Worx fabricated billet LED tail light (anodized black)
-LED rear blinkers
-LED Oberon front Billet blinkers
-ABS LED blinker Relay
--------Suspension--------
-Black XB Scg forks
-MC Moto-Worx modified XB Triple Trees with X1 stem (powdercoated)
-West-Tek rear shock front mount
-Penske rear shock
--------Brakes--------
-XB ZTL2 8 piston Front Brake caliper
-Hel black front brake line
-GSXR radial master cylinder
-Rizoma Billet brake reservoir
-EBR Front rotor/mounting hardware
-XB rear rotor
-Brembo rear hidden brake caliper
-Custom hidden caliper bracket
-Brembo rear master cylinder
-XB stainless rear brake line
--------Engine/Performance--------
-Borla Race Header tubes (black ceramic coated)
-Borla Race muffler (high temp black powdercoated)
-MC Moto-Worx Billet Air Inake with K&N Oval Race filter (powdercoated)
-Buell Race Tune
-Powdercoated starter (powdercoated)
-MC Moto-Worx fabricated billet aluminum pulley (hardcoated)
-Powdercoated XB rocker boxes (powdercoated)
-XB oil cooler
-MC Moto-Worx oil cooler mount (powdercoated)
-MC Moto-Worx modified Pegasus catch can (powdercoated)
-Updated style X1 exhaust hanger (powdercoated)
-MC Moto-Worx cut cam cover (powdercoated)
-Primary Cover (powdercoated)
-Updated bronze oil pump gear/primary chain adjuster/lifter anti-rotation pins
-Zipper collapsible pushrod tubes with billet bases (powdercoated)
-ASB front Billet engine mount (powdercoated)
-Fragola Performance black nylon oil lines
-Fragola Performance AN fittings
-Amsoil 20w-50
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  #3  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default

after the first year of riding, the bike came completely apart-



frame powdercoated



re-assembled with late model buell XB frontend and wheels (was going to do the rear swingarm conversion as well but i just like the uniqueness of the under bike shock to much and the XB swingarm to me doesnt flow as well with the tubular frame) Would love to build a tubular swingarm possibly in the future.





After swapping to a XB front I designed a dash to hold the factory gauges and fit in the shape of the XB housing. It was printed on a 3d printer (Seletive laser sintering machine) for the final usable part and works great. The material is sintered glass filled nylon. Also what the bar end mirrors are made from. I have since removed this dash and went with a motogadget speedo.



Here are the spacers i made to run the XB wheel on a tuber. (Tuber axle is 25mm, XB bearings are 30mm) Also shown is a modified ducati monster rear brake caliper bracket trimmed and clocked to hide behind the swingarm-





Needed a drive pulley for the bike. XB uses a 65 tooth and the Tuber uses a 61 tooth. Both factory pulleys are ugly and have different bolt patterns. So i made one that is a 61 tooth and looks like an XB wheel with the correct bolt pattern.



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  #4  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default

this was when i first thought it was finished....






One thing i never liked and thought looked out of place was the aluminum tail. Its unique but just doesnt fit. so.....












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  #5  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default

here are some of the parts ive made-

headlight brackets for the vrod head light




front drive pulley cover




air filter






penske shock reservoir to frame clamps







tail light housing







subframe and electronics tray




rear drive pulley




handlebar clamp and gps mount arm




rearsets and heel guards




oil pressure guage mount






shifter, linkage, mounting/pivot block




pulley guard/support




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  #6  
Old 25th June 2014
purpony's Avatar
purpony purpony is offline
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Join Date: Jun 2009
Posts: 55
Sportster/Buell Model: Buell X1 Lightning
Sportster/Buell Year: 1999
Reputation: 55253
purpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to beholdpurpony is a splendid one to behold
Default

over the winter i also made all new oil lines - Black nylon hoses with anodized clear aluminum AN fittings.



and the new seat- reshaped factory with gel insert and custom cover





in the process of finishing the new paint and calling the bike just about complete-




Last few modifications that I am looking into for this coming winter and should finally complete my bike are:

Ported heads
Cams
J.E.T dyno tune
Aluminum oil tank
Hydraulic clutch and master

and if i ever get lucky enough to find a set of Alpina tubeless spoked XB wheels (discontinued)
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  #7  
Old 25th June 2014
xHDrider's Avatar
xHDrider xHDrider is offline
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Location: ERIE
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Sportster/Buell Model: XLH Sportster
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Other Motorcycle Model: 650 Triumph Bonneville
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Default

looks sorts sloppy like a farmer did it in the barn.. I'm kidding looks great top shelf are you sure your name isn't Eric..

first class workmanship!
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883 / 1200 conversion, shrink ported high velocity heads, milled .020 off the compression side. stainless steel tulip conversion valves. 10:1 wiseco forged pistons. "W" cams, Crane HI-4E ignition module, forcewinder AC. mustang seat, Progressive springs, RK-shocks, fork brace. metzeler me880 tires, headlight modulator. PIAA intense white H4 bulb
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  #8  
Old 25th June 2014
NRHS Sales NRHS Sales is offline
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beautiful work!! I am just now learning how to TIG weld and hope to be at your level someday.
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  #9  
Old 25th June 2014
Phelan's Avatar
Phelan Phelan is offline
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Epic work as always Marc . I love the new colors!!
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  #10  
Old 25th June 2014
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ChinCactus ChinCactus is online now
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Wow that is amazing work! Thanks for putting it out there!
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