When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
The Evo engine is taller and wider (viewed from the side) than the Shovelhead engine. I think it is best to raise the upper rail over the rear head enough to get about 1" clearance over the rear head valve cover. I think it's okay to notch the seat post for clearance (you will wind up cutting it approximately in half) but I did a different mod rather than notching. I do not recommend notching the upper rail; it makes the frame too weak at that point. I raised the whole assembly by detaching it back at the seat post and the front frame rails. I stretched the front rails a little over two inches and maintained close to the stock rake. Then, of course, you will need to make a custom upper motor mount. If you are doing the frame mods yourself then the upper motor mount is no big deal. With the frame stretch, you will need a longer front end.
The Evo lower motor mounts and primary cover mount are the same as the Shovelhead. The front cylinder should clear the frame front rails, no problem.
As far as exhaust goes, any Evo (of course) or Twin cam exhaust will bolt up to the Evo engine (same mounts/spacing for both engine families). I used a stock exhaust system from a 2003 Softail Standard. I was amazed at how easily it adapted to the Shovelhead frame mount. A Twinky exhaust on an Evo in a Shovelhead frame, whoda thought?!!
I had a hell of a good time doing this. When I bought my bike (1979 FXS) from a salvage yard, the Shovelhead engine was long gone and an Evo was in its place but the previous owner had done a moderately poor job modifying the frame so I modified it to my satisfaction which entailed cutting off his work and making up my own stuff.
Notching the frame is alright if you do it right. But the best thing to do is heat the seat post and backbone and beat it with a bfh. That is what harley did on my'85 FXWG.
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.
Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.
Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.