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Nov 7, 2017 | 01:04 PM

#21

Hannibal Smith

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Road Captain

Joined: Jan 2013

Posts: 546

Likes: 606

From: Out West

Got to take an inch out of the rear fender. I take masking tape and run it dead center. I then just grabbed some rattlecan, and marked it. This is my cut guide.

I cringe everytime I see someone chopping a fender with a cut-off wheel, but you have to use the tools that are available.

I then took it to a bandasw, and got a super even cut.

With a near perfect mating surface, and with proper welding, you can get a distortion free job. I never had to use an English Wheel or a hammer to even things out on this one. I don't need Bondo to get it even either, this method really minimizes the work to get it paint ready.

Quote:

Originally Posted by DanHappy

Do you have a shop that does this kind of work or are you an out of control hobbyist?

I used to build race bikes for clients years ago, but now just build for myself. I design and make military weapons stuff as my day job, so I use my shop to do bikes now.

I work on them when I am in the mood. So basically at this point, I am an out of control hobbyist

Making a Marchesini wheel fit a Harley. I made stainless steel wheel internals so that I could run a 3/4" axle.

I made the axle and nuts from stainless steel, and also made stainless frame inserts on the rear dropouts of the frame.

I also made lift stand buttons from 7075 T6 aluminum that go into barrels that I welded to the frame. This makes chain adjustments and wheel maintenance easy. It's a carry over from my race bike days.

I made the sissy bar from stainless steel, and you can see my first mockup on that part.

I am also running a rear Brembo caliper, and made a hanger to tie it into the rear disc.

Last edited by ChickinOnaChain; May 15, 2018 at 11:08 AM.

Nov 7, 2017 | 01:38 PM

#22

TORQUEY

Seasoned HDF Member

Joined: Aug 2010

Posts: 5,173

Likes: 177

From: East Coast

Wish I had 10% of your ability with this...

Nov 7, 2017 | 01:50 PM

#23

Hannibal Smith

Thread Starter

Road Captain

Joined: Jan 2013

Posts: 546

Likes: 606

From: Out West

Since a Marchesini sprocket is made for a narrower race bike chain, I had to make a sprocket that works with a 530 Harley size chain. Its a 48 tooth.

Made my own alternator cover, it's not done in the pic, but it's getting there.

Made a rear fender tie-in that goes on the bottom. I just took a really thin strip of aluminum, and got my angles. I then machined a part, and made a bend jig.

Made a carb support, and it follows the lightweight theme.

I am running all my wires exposed and inside stainless sleeving like on a payphone. I made a "lollipop" to hold the grommet to run to the coils, and made a clamp that goes on the oil pump to route it.

Never mind the cut rubber hose, that was there to test fire the bike before I got in too deep! It fired on the third kick, and the ignition was just slapped on. When I get her dialed, she's gonna be a 2 kicker all day.

Made a seat hinge to go with my custom seat.

I made a stainless steel seatpan that follows the frame, and rides flush on top. It's a chopper, so I already have no rear suspension, straight pipes and a drag bike mill in the frame. What's having a soft seat going to change!

The leatherwork was done by Clinton Case at Bruiser Custom Cycle in SoCal. He did a fantastic job. I wanted to stay classic, and had it hand-tooled like a Western saddle. Nothing crazy or trendy.

Last edited by ChickinOnaChain; May 15, 2018 at 11:09 AM.

Nov 7, 2017 | 02:24 PM

#24

DaveE

Ultimate HDF Member

Joined: Oct 2013

Posts: 6,536

Likes: 1,035

From: Pennsylvania

Just amazing quality work! My hat's off to you

Nov 7, 2017 | 02:38 PM

#25

Hannibal Smith

Thread Starter

Road Captain

Joined: Jan 2013

Posts: 546

Likes: 606

From: Out West

Thanks all- Got to go dig up some more pics.......and get back to work!

Nov 7, 2017 | 02:44 PM

#26

Oldskewl

Seasoned HDF Member

Joined: Jul 2013

Posts: 11,185

Likes: 7,961

From: In my head

Everything fully machined, ARP fasteners. Doing it right. Nothing sweeter than kickstart shovel, especially one handmade like this.

Nov 7, 2017 | 04:42 PM

#27

Hannibal Smith

Thread Starter

Road Captain

Joined: Jan 2013

Posts: 546

Likes: 606

From: Out West

Drilling the backbone for a hidden gas tank mount.

I made an aluminum block that takes drill bushings so that I could locate and center my weld in cylinders. I taped a little level on it so that I could see if anything shifted when I hand drilled through the frame. I used a super powerful 1/2" drill, and it took some muscle to fight it.

I want these as straight as possible because this will ensure that my tank gets mounted without any tweaking loads. I have found that if you fight a tank or even a fender to mount it during the final build, you run a risk for either paint, metal, or both to crack. Especially on a Harley. Just going the extra effort to minimize it pays dividends down the road. Sometimes you are going to have to push/pull a part into position to mount it, but the less the better.

Nov 7, 2017 | 05:41 PM

#28

not_so_newb

Elite HDF Member

Joined: Oct 2009

Posts: 3,922

Likes: 826

From: Toronto Canada

i probably only understand 30% of what you're doing , but damn it looks good !
i also get the feeling you could have just started with some aluminum and steel and built the whole bike except for the tires . probably only would have taken a couple more days too !

great work , looking forward to seeing more .