Here is a quick run down on some work I just finished, I still have to fit the AIM VPC,
its still coming out from the states and once I've fitted that I'll get her on the dyno.

My bike was already at 106, had 585 easystarts and SE Clutch spring.
Ran REAL well, this thing was no slouch, with stock heads and the dreaded short shots (which I loved) it was at 98hp/115tq.
So anyway I decided to do the heads so here is a list of new bits I've fitted.

S&S lifters #33-5350
60mm zippers thundermax 1 piece throttle body - #109-660
D&D Bobcat exhaust
HD SE PHAT RED Spark Plug Cables - 31937-99B
NGK Iridium IX Spark Plugs - No 6046
zippers A/C #117-150 - including filter
gaskets & Filter
Headwork is by a local guru, Mark Hood - porting, 1.900-1.615" AV & V valves,
AV & V 0.640" springs, seals, man-decomps, 0.040" gaskets
Crane HTC-296-2, 0.620" lift Cams, cam chest gaskets & O-Rings
2 x Cam Timing chain tensioner shoes
S&S Roller Rockers - Forged 900-4065A

AIM VPC is on the water (or air lol)
Dyno tune by Neville Lush Racing to come.

Also fabricated some 2" extensions for my forward controls....

CR is set at 10.43:1

pretty happy the bike started up well with no unwanted noises and no leaks, top end got oil straight away.
I trial fitted the rocker covers and as I knew, had to die grind the webbing away to get clearance underneath.
Have only ridden around the block a couple of times as needs that tune but it feels like it is about 20 cubes larger!!
can't wait to get her running right
I set lifter pre-load at about 0.140" no noise at all from valve train even with 620" lift and roller rockers.

some pics from along the way...

Before..


Day 1 pull down..


Measuring Deck Height to work out gasket thickness to get optimal comp...


Zippers 60mm TB compared to stock..


Head comparison...


Heads and 60mm TB on..


pic of all new parts (roller rockers and vpc were pasted on as didn't have them yet ha ha)


D&D Bobcat..


some completed pics..



I cut out the centre of the filter and fitted a bit of lexan and machined up a stainless ring for the air cleaner....

 

Nice!!
Scott

 

nicely done project, suits my tastes. The red throttle body really works.

Q: I cannot see what you did with the head vent re-breather lines, to the TB. Stock are preformed hoses that split or crack.

 

Never mind, I see the re-breather lines are part of the zippers A/C kit.

I rather like the stock A/C on my bike, but as aforementioned problem with the breather lines splitting, I may have to change the A/C assembly out.

 

Thanks for the Thread! Builds like this - always something to learn, eat this stuff up.

Looks like the intakes on the cylinder heads were opened up, do you know what Mark Hood had to do to match the Zippers tb?

What handlebars are those?

Love D&D Bobcats, almost got them myself but was a bit worried about rear shock bolt interference with extended shocks(13")...IMO - best looking 2 into 1 bar none.

 

Super nice build. You will love those cams. If/when you are into the motor again, consider going to a .036" or even a .030" headgasket to get static CR between 10.5 and 10.8:1. You will be rewarded with a stronger bottom end that will make a noticeable improvement in your riding satisfaction.

 

Nice man! Gonna be a heck of a ride. I really like those bars too.

Congrats on the build and thanks for sharing.

 

Thanks guys, I fabricated the bars myself, I'm a fitter/welder, 4th set I've on and the most comfy and nice and solid, no flex like I had with the apes and custom made so perfect height. I sort of picked all the best bit of previous bars and fitted them into these! I don't like pullback risers but straight risers can look a bit skinny so I curved the risers out towards the ends of the bars..
My pistons are 0.001 above the cylinder so with a 30 thou gasket I would have had 29 thou squish, I thought that was getting a bit tight so went with a 40 thou HG and pretty happy with all the math... We'll see how she goes.
Yes my head man port matched the runners out to 1.780' same as the zippers intake bore, all done.
Bobcat is the only 2 into 1 that I like the look of and have only heard good things about it. I don't think you would have any clearance issues with your shocks with this pipe as the muffler turns out away from the bike quite a bit there, gives heaps of room. Bloody good fitting pipe. I modified the gearbox mount for it though, gave it one more hole in the gearbox to mount to, probably not needed but I always beef things up a bit!

 

Great pics thanks so much for sharing. Bike looks fantastic and I really enjoy learning how these changes affect the bike. Awesome job!

 

Really like the lexan on the a/c, it'll be neat to be able to watch the butterfly valve work on the tb