I'll be installing a David Bird hardtail on a rubbermount. I will post my progress here along with some tips & tricks to along the way.

I believe it's an 06. This is how I received it



I knew I would be stripping it completely so there was no need to do it on a lift but stabilizing one of these on a jack can be a pain.

I bolted a scrap piece of 1.5" half-round to one of the jack plates.



It positions the rear most lower frame cross member perfectly like this.



I was able to strip the entire bike without strapping it down.



A couple hours later...



That's where I stopped for now. The next step will be to cut everything off of the frame leaving the main loop. I will be able to show more progress this week. Updates will be a little spotty because my shop is pretty full right now.

Thanks for looking!

 

Looks like a fun project. I'll be watching for updates. Good luck!

 

Looks good! Love the front end.

 

 

yes!!! ive been waiting for this... pleas take alot of pics on the more important steps. ive been wanting to do this for 2 years now.

 

I've been a little lacking on taking pics. Using a manual for the dis-assembly & the instructions that come with the hardtail is exactly spot on.

Here it is now. The rest of the build, however, will be custom. I'll get down on pics of that.

 

Bro??? What's the progress on this bad boy.

 

Curious, when I had my XS I remember it was suggested to leave the engine in the frame when cutting/welding in a hard tail to avoid spring back and the frame ending up out of line. Is the sportster frame rigid enough that this is not an issue?

 

We decided to get to this point then plan what direction to go with parts that are available and what I'll either make or modify. Currently waiting on parts. I should be able to show progress soon.

None of the crucial areas were disturbed. When chopping as XS, the rear downtube is removed leaving all of the motor mounts unsecured.

I use different methods depending on what part of the frame is being modified.

Although I would never suggest using the motor itself as a fixture to keep the motor mounts in tact, I do use fixtures for the same reason.

This is an Ironhead I'm hardtailing now. I will ultimately do the tail in the frame jig but the fixture keeps everything in place until then.



This is a big twin frame I'm also doing right now. There is a 3/4" thick aluminum plate keeping the motor mounts in place. The transmission mounts will stay in tact because I didn't cut that side of the rear downtube...



In this pic you can see that the rubbermount Sportster's main frame loop has not been opened up so the motor mounts will not be affected.

 

Brotha. Any progress on this thing.