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To do the bottom the only way I can figure is to do them by hand and use a hand rivet clincher. I'm sure that HD had some type of arbor press or hydraulic press they used for the bottom parts.
Those pieces are the only parts I have put back on so far. I need to get the other parts into the platers for cad finishing and clean up the locking mechanism in the meantime.
Last edited by panz4ever; Nov 22, 2020 at 10:13 AM.
Exhaust is finally in place. When I bought the bike it had a dual exhaust. The system was the "extra quiet" version. At the time it was too quiet for me. Went to a single exhaust and took out the welch plug at the end. Ran that until I decided to switch to the cigar shaped muffler. When I started collecting parts for the bike some 15 years ago I found an OEM to go with my non-altered one. Managed to gather up the complete exhaust sytem sans the cross-over pipe (found one but it fit like ****).
Indent on header pipe needed for sidecar mounting hardware. Indent on bottom of crossover pipe needed for clutch pushrod.
Fresh chrome and ready foir installation. (Still have a couple of bolts I need tp parkerize on each side of the exhaust.) Heat shield installed. HD did not introduce the heat shield that covered the crossover and solenoid assembly until 1966. This shield was just a one-year run.
Pic of the end of the extra quiet muffler. MoCo in the literature states it is not recommended for single exhaust systems (meaning I suppose they are pretty quiet and restrictive...probably the reason I took them off). Picked up some period correct mufflers I may try if I do nto like the sound of the the stock system. The original stainless muffler clamp is too large. Muffler comes with a muffler clamp that fits the diamter. Needs to be custom fit tho.
I chromed both header pipes. Would not have been that way from the factory, would have been painted silver (or maybe just a natural finish?) and the slinky cover would have gone over both parts. Didn't wanty to have to do a custom fit for the clearance of the crossover nor did I want to figure out clearance issues with the sidecar components, so they got chromed.
Last edited by panz4ever; Dec 1, 2020 at 05:29 PM.
When I got my '65, it had single exhaust. There was a complete dual set up amongst the parts I got with the bike including two NOS Super Quiet Mufflers. Previous owner said he had trouble lining everything up so he did not install. I did and it sure sounds great.
When I got my '65, it had single exhaust. There was a complete dual set up amongst the parts I got with the bike including two NOS Super Quiet Mufflers. Previous owner said he had trouble lining everything up so he did not install. I did and it sure sounds great.
Good to know. Thanks. And getting it all to line up correctly was definitely a chore. Thinking the sound at age 73 will be a bit more to my liking than it was at age 22
When I got the sidecra it came with a bare two-fender brace and an aftermarket three-fender brace. The 3-fender brace was void of any holes and I had to add the bracket to secure the step.
I sourced an original one. Has a few extra holes that I will have to weld (like at least a dozen), but the the original cut outs and holes for the rear light, the top fender light and the stainless trim is all there.
Couple of days ago I decided to finally attach everything needed for the sidecar wheel to check fitment. I even pulled out the line to figure how it would be run. That is when I discovered why HD went from a three-btrace sidecar fender to a two-brace sidecar fender.
Ended up spending an entire afternoon removing the fender brace. Tok a lot of careful grinding and a 1/8th drill bit to get the original rivits out. To make matters more interesting the top rivits had been brazed. Now I need to weld the over-sized holes in the two-fender brace, redrill the correct 3/16 inch holes and use new truss rivits to attach the brace to the fender. Then I will do one more complete fitment before taking it apart (again), having the fender bead blasted and then having the holes filled.
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