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2003 FXD - Complete Rebuild

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Old Jul 13, 2025 | 10:00 AM
  #91  
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Got the front forks broken down, need to make a few small cosmetic repairs on the lowers, then will get them and the wheels out to powder coat.

Did some measuring so I can make some spacers for the longer axle. Pretty sure I will have to make some hub spacers also to get the brake discs out a little further , or I can space the Brake calipers inward. Anyone have any insight?
Tubes are in good shape fortunately, one thing at least to save some cost.
Tubes are in good shape fortunately, one thing at least to save some cost.
Few small dings I need to weld back in and clean up. Overall in good shape.
Few small dings I need to weld back in and clean up. Overall in good shape.
Stock FXD axle on left, Stock 49mm axle in middle, and the Vulcan conversion axle on the right. Definitely going to need some spacers.
Stock FXD axle on left, Stock 49mm axle in middle, and the Vulcan conversion axle on the right. Definitely going to need some spacers.
Still waiting on the calipers, so won’t be able to mock that up until I get the lowers back from powder.

 
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Old Jul 14, 2025 | 09:06 AM
  #92  
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Originally Posted by misfitJason
DAAAYUM! Thats used Sportster money there.
 
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Old Jul 15, 2025 | 03:30 PM
  #93  
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In keeping moving forward, worked on the lower tree. The fork lock on the later model bikes looks like it is a pin that is engaged into a tab that is on the lower tree. It would not have been in thew way but looked odd. So I filled the hole with weld, then ground it off to look like the other side. Also added weld to the fork stops to make them taller so they hit the frame correctly. These, the fork lowers, and the wheels and the fender rail covers will be going to powder coat this week.

Once I get those back progress should take a big jump. Hopefully it wont be 110 in the garage either. I have a small a/c I can run out there, but no money left to run it after buying that swing arm.

Cut off the fork lock tab and added some weld to make the fork stops taller so they engaged with the frame properly
Cut off the fork lock tab and added some weld to make the fork stops taller so they engaged with the frame properly
All cleaned up and ready for powder
All cleaned up and ready for powder
All cleaned up and ready for powder
All cleaned up and ready for powder
 
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Old Jul 15, 2025 | 09:28 PM
  #94  
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tagged in. A+ work.
 
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Old Jul 16, 2025 | 12:52 PM
  #95  
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Great skills, top notch work...

I'm enjoying this thread..!
 
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Old Jul 20, 2025 | 01:19 PM
  #96  
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Swingarm arrived and got it installed. This thing is f$&@ing sweet. Very well built and finishes are top notch.

also got he new transmission pulley installed. Used the Jim’s Mega Nut. Was so much easier than the stock setup. Didn’t have to uninstall and rotate spline by spline the get the holes to line up. Found a hole first shot within specified torque range.

Started working on getting primary mounted, but somehow I lost the mid control inner shifter shaft. Need to get everything organized again, limited space makes this process a little hard.




 
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Old Jul 20, 2025 | 01:42 PM
  #97  
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All of it is striking, looking great
 
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Old Jul 21, 2025 | 01:43 PM
  #98  
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That swingarm is badass
 
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Old Jul 25, 2025 | 11:22 AM
  #99  
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No real updates. Missing a few small pieces of hardware, and couldn't find a real world conversion for, so had to order though HD.

In the meantime, started designing a custom tank emblem. Was going to sandblast and clean up the original ones, but the material is very cheap, and the previous owner tried to touch them up, and dinged them all up. Going for a modern take on the original 100th anniversary badges.

Also need to start looking for an exhaust as most seem to be not in stock and long ship dates. Not sure what I want to do. Pretty sure I want a 2-1, though I have always liked the looks of the short shots. Also not sure black will look that great, and not a huge fan of chrome. The raw stainless look doesn't do much for me either. Most likely going to get a raw 2-1 and either Cerakote it or hand finish it will a non-directional satin finish and do powder coated heat shields.
 
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Old Jul 25, 2025 | 11:28 AM
  #100  
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Originally Posted by malfvnction
Swingarm arrived and got it installed. This thing is f$&@ing sweet. Very well built and finishes are top notch.

also got he new transmission pulley installed. Used the Jim’s Mega Nut. Was so much easier than the stock setup. Didn’t have to uninstall and rotate spline by spline the get the holes to line up. Found a hole first shot within specified torque range.

Started working on getting primary mounted, but somehow I lost the mid control inner shifter shaft. Need to get everything organized again, limited space makes this process a little hard.

Is that a test fit? Shouldn't your inner primary cover be installed?
 
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