Project: Vintage Racer

Part 1

First off I want to set the record straight, I am not building a year specific bike.  The idea behind this is to build a vintage style mini-bike that can ride the pro class.  The bottom line is we have to race against bike with 3-4 times the horse power, so we need to pull out all the stops and make something that is somewhat competitive.  The look for this bike will be a '77-'78 XR75, however it will have big wheels (19", 16") and a XR100 motor. 
     In order to start, you need a frame.  Any XR (75, 80, 100) frame from 1978 - 1984 will work (on XR100 frames you have to cut the tank stops to fit an older style tank). The next step is to get a XR100 twin shock swing arm, wheels, and airboot. The tank, plastics, and seat will be a '77-'78 XR75.   However, on the seat and plastics various XR80 years will work also.  Try to get a complete a bike or frame as possible, little things like grommets and motor bolts are not only a pain to get, but can be expensive from a dealer. It's also good to know,  that if you buy rattle canned painted plastic, you can use paint remover (gel type) to get rid of it and not hurt the plastic.  After you compile your parts, you will need to paint them.  In order to make the most sano bike around, we just don't rattle can them; we take them to the best motorcycle painter around, Rick Carro in Newport Beach.  The picture below doesn't do them justice since I'm color blind and I can't adjust the hue and saturation properly, but he paints and clear coats everything and even clear coats the stickers so they can stand up to the abuse of racing. He also paints the backgrounds on the number plates.  Since my frame and springs were in such bad shape, I had to sand-blast them before he painted them, but if the original paint is somewhat OK, you can use that for a base instead of primer. 
    This is where I'm at now, part 2 will be the assembly.

It's easier when you buy a bike to make sure it has all the grommets and spacers.

Part 2

The fastest and easiest way to build a bike from scratch is buy someone else's bike, which is exactly what I did. I picked this up for the price of a good 120 motor.  Of course now I have a bunch of vintage parts laying around. 

Part 3

I'm trying to find my pics of the completed bikes before I sold them.