Another Custom Rebel Project - Honda Rebel Forum
 16Likes
Reply
 
Thread Tools Display Modes
post #1 of 32 Old 07-27-2016, 09:28 AM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Another Custom Rebel Project

1. Bought a barn Rebel - not running
2. Stripped it down to bare frame
3. Cut mounts off frame that won't be needed - exhaust / rear peg flange, rear fender extensions, air box and helmet lock tabs.
4. Reassemble a rolling frame to build upon
------
5. The first fabrication job will be the exhaust. Got a 4 into 2 Suzuki sport bike exhaust that I'm going to cut up and reconfigure into a 2 into 1 Rebel exhaust. The muffler will probably be on the right side but that's not certain at this point.

Hoping you find it interesting - I'll add some pics as things progress.
Nephets and jim ray like this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
Sponsored Links
Advertisement
 
post #2 of 32 Old 07-27-2016, 12:47 PM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Here's my trusty assistant for this project.





Bucket O' Parts





Trimmed off the rear fender supports





Trimmed off the exhaust supports





Here's half of the sportbike exhaust I'm using to fabricate a new exhaust.





Had to cut the manifold end off to turn them down to fit the Rebel head. They were 2 mm oversized.





I will be welding them back on tonight after work.





Left over from the cut up half.





Is this a bobber shadowshack?

SoichirosREBELlion likes this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
post #3 of 32 Old 07-27-2016, 07:01 PM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Well, I'm pleased with the welding job but not with my lack of measuring and planning beforehand. I think the headers need to stick out further from the engine so they can meet and run parallel to a point under the engine.





The left pipe can't wrap over the frame to the right the way it is.







Or maybe bring both pipes to the center and curl underneath where I can hide the welding of 2 into 1.







Things to think about.


That's it for tonight. Thanks for watching.
maggimia56 likes this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
 
post #4 of 32 Old 07-30-2016, 01:03 PM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Plan B on the exhaust after looking at some other projects on here.

I wonder what's inside the stock exhaust pipes?





this looks promising





fitted and tacked





how does it look so far?





enough fun for one day, more fitting tomorrow i hope - i need to paint the trim on the house





what do you think?

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
post #5 of 32 Old 07-30-2016, 10:53 PM
 
Rebelimiter's Avatar
 
Join Date: Jul 2016
Location: San Jose
Posts: 92
Lookin good! I kind of liked how your first set ran along the same lines as the frame. If you followed the bend at the bottom you could have gotten a hidden frame look from the side with duals. But I guess the plan was that sweet single muffler from the beginning, so I think it worked out really good with the chopped stock set. That thing should sound throaty! Lookin forward to seeing whats next.
01-7700 likes this.
Rebelimiter is offline  
post #6 of 32 Old 07-31-2016, 06:27 AM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Thanks for the encouragement! I'm going to weld up the seams and add a mounting tab back to the frame today. Next project will be the rear fender. I bought a Shadow VT1100 front fender to put in the rear. Just noticed that this bike has a 140 tire in the back. The VT1100 fender fits the tire well. I'll need to decide how to support the fender off the swingarm.



Here's the exhaust tacked up and ready for final welding. It's considerably smaller and lighter than the stock dual exhaust. Cheap beer for scale.





A view from down under.




another angle.




another





mounting tab made from the original pieces





It's welding day!!! What will it sound like? I don't think I can wait until the bike is finished to find out - I have another Rebel that is mostly intact to try out the exhaust.
Rebelimiter likes this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
post #7 of 32 Old 07-31-2016, 03:00 PM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Mounted the exhaust on the wineberry Rebel to hear it. Sounds too good to be true




The rear fender mounted to the swingarm - enough for today.



Rebelimiter likes this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
post #8 of 32 Old 07-31-2016, 04:43 PM
 
Rebelimiter's Avatar
 
Join Date: Jul 2016
Location: San Jose
Posts: 92
Wow that sounds great! Almost like a full sized bike! Im just wondering if you'll have any clearance issues in right turns... muffler looks a little low, Im guessing you wont be lowering the bike at all. That rear fender fits perfectly too, if you're still looking for a mounting solution this is what i did (scroll down to 4th post). Best of luck!
Cheers.
Rebelimiter is offline  
post #9 of 32 Old 07-31-2016, 04:58 PM Thread Starter
Moderator
 
01-7700's Avatar
 
Join Date: Oct 2011
Location: Maine
Posts: 1,811
Garage
Quote:
Originally Posted by Rebelimiter View Post
Wow that sounds great! Almost like a full sized bike! Im just wondering if you'll have any clearance issues in right turns... muffler looks a little low, Im guessing you wont be lowering the bike at all. That rear fender fits perfectly too, if you're still looking for a mounting solution this is what i did (scroll down to 4th post). Best of luck!
Cheers.

LOL - I subbed in some v-twin sound as a joke. The new muffler sounds similar to the original pipes.
Aeufracio93 likes this.

1985 Rebel 250 Project ... Ruckus ... Shadow Spirit 750
Keith from Maine USA - Banning Spammers since 2016
01-7700 is offline  
post #10 of 32 Old 07-31-2016, 05:03 PM
 
Rebelimiter's Avatar
 
Join Date: Jul 2016
Location: San Jose
Posts: 92
Quote:
Originally Posted by 01-7700 View Post
LOL - I subbed in some v-twin sound as a joke. The new muffler sounds similar to the original pipes.
Haha u got me good
Rebelimiter is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Honda Rebel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

 
For the best viewing experience please update your browser to Google Chrome