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2001 xl883h mid-glide front end.

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  #21  
Old 02-02-2016, 11:49 PM
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Originally Posted by botoml
How much did your front end conversion end up costing you?
Would you mind listing the parts and prices?
Wish I could give you an accurate representation of the price, but a lot of the parts I used were take off parts that I bought for next to nothing. Some of them were given to me. I will try and list everything I used though. Not including the tools I needed to buy to machine the hub itself.

From a stock mid glide front end:
Top tree
Bottom tree (with stem)
Tubes (2)
Compression springs (2)
Rebound springs (2)
Damper tubes and expander seals (2 each)
Slider bushings (2)
Tube Bushings (2)
Seals (2)
Seals retainer clips (2)
Seal seating washers (2)
Damper tube locator dowels (2)
Damper bolts and copper sealing washers (2 each)
Fork caps (2)
Fork cap o-rings (2)
Fork oil (2 pints)
Dust seals (2)
Decorative seal covers (2)
Right slider
Left slider
Axle clamp bolt, nut, washer, lock-washer
Axle, nut, and washer
Pinch bolts for trees (4)
Pinch bolt for stem
Stem adjustment bolt and washer
Stem bearings, upper and lower dust shield

Other recycled parts I used:
21" wide glide wheel hub set for 3/4" bearings (requires machining)
16" rim, spokes and nipples
Aluminum 25mm wheel spacers (requires machining)
Hub spacer for 25mm axle (requires machining)

New parts required:
Wheel bearings (25mm)
16" tire, tube, and rim strip

Parts required for brake:
Stock disc and bolts (2001 xl)
Stock brake caliper (2001 xl)
Stock brake caliper bolts (2001 xl)

Other items to mention are that I had to measure to find the wheel offset when lacing it, so that the tire was centered between the forks. Wheel spacers were machined to center the disc in the caliper body. I also had to bend the fork lock bracket welded to the frame down slightly. The headlight 'eyebrow' had to be modified slightly to fit under the top tree. Could be avoided if you go with a lower tree mount, as the lower tree is already drilled for it. Factor in a different headlight bucket and bracket though. The stop doesn't contact the tree stand-offs as much as I'd like so I'll probably take it apart and machine some excess material off the lower tree where the bearing sits. I'll be sure to take pictures.

All in all I think I have about $175 in the front end parts. $180 for the tire, tube, rim-strip. $70 in tooling. Not to mention a bunch of time making it work.
 

Last edited by pFlarey; 02-02-2016 at 11:58 PM.
  #22  
Old 02-07-2016, 10:56 AM
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Got the exhaust welded up. Just needs some wrap now.
















 
  #23  
Old 02-07-2016, 11:37 AM
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Looking good, so far! Keeping it classic, nice.
 
  #24  
Old 02-07-2016, 11:42 AM
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Nice! 👍
 
  #25  
Old 02-27-2016, 12:43 PM
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Handlebars mocked up. Have an internal throttle coming soon. Playing with the idea of a hydraulic clutch. Wrapped pipes. Made an intake and got breather bolts installed.


















 
  #26  
Old 02-27-2016, 04:17 PM
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The bars look great and I dig the vents.
 
  #27  
Old 03-19-2016, 02:52 PM
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Ok so, the internal throttle is installed. I drilled the right side riser bolt to route the cable. The cable itself is made up of two separate throttle cables. I needed to include an adjuster, and wanted to hide it. Ended up under the fuel tank. I think it turned out better than expected.










 
  #28  
Old 03-19-2016, 02:56 PM
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Forgot to add a pic of my license plate mount. A friend had a couple made and gave one to me. Stainless too!




 
  #29  
Old 03-20-2016, 02:32 AM
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Looks good!
Was the tightest angle inside the handle bar?
 
  #30  
Old 03-20-2016, 08:30 AM
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Originally Posted by AKFXD
Looks good!
Was the tightest angle inside the handle bar?
Guessing close to 90°. It's a little stiff. A compromise for cleaner handlebars I suppose.
 


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