electrics

First off, it's flippin cold! so it's one stage at a time then thaw out!
Used the old loom from the voltage regulator along underneath the frame incorporating neutral light wire, oil light wire, starter lead with OEM circuit breaker, once in place the circuit breaker wires will need to be shortened as the routing is shorter than OEM I ran the wires already with heavy duty cover under the starter then up to the electric box. Would be nice to hide the lot but I'm not putting new wiring throughout as this is my first attempt and haven't foggiest as to where to drill holes in the frame for said wiring! so I have just run the Hi4 wiring through the frame as at least that is one less set of wires on view at least, and in some respect leaving the wiring easily accessible isn't such a bad idea for the newbie!
I've also come across some wiring loom covers that are all shades of colours so might just make a feature of them!
Lessons learnt:
I had to remove the front sprocket cover, front exhaust and pegs just to fit one wire connector (neutral light) half hours extra in the cold. Main reason was to eager to get her put together so I could sit and play and admire my work so far.... vanity pure vanity!!

I have also kept some of the main wires to and from the old fuse box and starter relay mainly so I have some idea of what goes where, to date I have about 12 different wiring diagrams plus a couple of online links. By switching between them and getting to understand how the setup works it is slowly making sense.
A couple of pictures for what it's worth

 Hi 4 in place

 Ignition wire for Hi4 

Other wires are from rear light

OEM wires from regulator not yet fed under the starter, ignition and fuse box already in place

Wiring

Well, spent a couple of hours sodding about with the wires, I have pulled more wires off the OEM loom, leaving just the relays, starter, ignition and fusebox, that way life will be easier, I have ordered a new fusebox (cant re use the OEM space wise) and a few dozen miles of wires as I think it will be easier for the novice at large! :O). The box is in place and I am fairly pleased with it not perfect ( i try honestly) but if it was perfect it would be a mass produced OEM one ha!
couple of pics below

Wires will enter underneath and lid has a gap at it's widest point for a air flow. 

Also one of new risers 

Bits on Bobs

Got 50" of belt blank, brass buckles & rivets from fleabay for a tenner, so that's the Battery sorted! Electric box painted, gone with black, holes drilled for wiring just need to  make the lid and mount might even be this weekend!

The Electrics

Spent a few hours messing about with the OEM wiring loom! and trying to figure what to keep and what to throw. It would have helped if the OEM wiring diagram in the Clymer Manual had the right colours listed! nothing like what I have at all!
I will be making a new indicator loom from scratch as I will be using LED's and the new ignition switch will be fun as the OEM has all red wires where the instructions show black, red and white !  Below is what's left and will it all fit in the box !

Cos i can

To the world


kiss my fucking ARRGGHHHarse


there that's better!

New battery

New battery tiny compared to original! Gel type can position it any old way which opens up some new ideas 

size: 

Length 150mm, Height 110mm, Width 87mm in old money about 6 x 5 

according to quadcam guys this is good enough to fire up a '94 sporty backed up by quiet a few using it was surprised to find it over here cost was £42 delivered, ebay were asking £60 odd plus postage so a bargain 

These batteries were not listed when I started my research for a smaller battery turns out it is standard for the Honda ST1300! 

Frank flut for that clutch sorted and adjusted I have gears!

soon be back...

in the garage! The DIY is all but done a nice shiny sheet of ally turned up this week for a couple of brackets and a electric box for under the seat so once I finished the grouting and the sealing...........

Censorship

Well to the few that might have a look at this site in passing I feel the need to comment on something that started a good few months ago, this is my opinion and no offence is aimed at the good people that looked after the forum except that I think someone somewhere lost the plot!
When I decided to finally get on with what I had thought about and dreamed of for years and that was to build myself a custom Harley. So I scoured the internet and found Chopperbuilder, I joined, read and learned from many people on there and it gave me the confidence to make the start, a lot of friendly non judgemental advice and ideas along with a laugh or two.
Then for no reason one night I went on the forum and it had been changed it was now The Boardtracker and the design had changed. There then ensued great debate! some liked some didn't but mostly people were pissed off because none of us were told about it beforehand, not even a poll. It became a bit nasty and people were getting fed up, the annual meet was cancelled which caused even more annoyance. People voted with there feet and the forum became quiet and almost to a halt, a few of us I suppose partly through loyalty kept posting answering the odd post etc.
Then a few months ago one kindly soul (cheers for trying Tricky!) found a pub with a field and suggested a get together, many said yes including me as I missed last years through all sorts of reasons and one or two on the forum I owed a pint or three for the help they offered over and above the bike building requests, a shite time in my life which they rallied around and offered friendship. Which will not be forgotten.
Well the pub was sorted, weekend was booked off, it would be a 500 mile round trip for me but I could visit me mum and sister on the way so it was worth it!
But, in life shit happens many started to pull out, fuck, it ended up  with just 3 people, me included, had said we would go! Well, it was cancelled a pain but not the end of the world.
So I posted a reply, saying "no worries shit happens" when it was posted the shit was shown "s**t" so built in censorship? tried to post again by editing the post and adding another shit! again bleeped out.
well for fuck sake, since when was having a shit a problem there are far worse words. I was tempted to add as many "naughty" words and see what was or wasn't "bleeped" but in an attempt to be grown up I changed my mind and tonight removed "the Boardtracker" from my favourites.
I know that most if not all people have either always been on Britchopper or like myself migrated over and a great bunch of nutters would be hard to find!
But it is a shame that it went that way and perhaps we will never know the whys etc. and I fully understand the need to for censorship but for goodness sake shit?

secret building!

Just to prove all is not lost!
I managed to sneak into the garage to (shush!) make some clandestine pipework for the oil lines, first time for everything never used a pipe bender before not to bad just a cheapy from ebay but done the job the tool could do with a couple of mods to make the bends cleaner but it's the bike I am modifying so that can wait! even got to sit on it and go brum brum :O) I even fitted another clutch lever having decided to go with alloy look over black!

Dont tell the missus!

Taking the Rise!

New 3" Risers arrived today quick swop and more than happy, except having took the picture it shows up the dust on the bike.

As things have come to a halt, waiting for the risers as the poor bloke who sells them got took into hospital with chest pains, and the bathroom needs tiling (been putting it of for several years!!) and having spent the weekend tiling and now me back has had it. I had a rummage through the pictures on the computer and thought I would stun you with some previous rides!

No particular order:
Transalp with our faithful old Westie in her custom topbox! She went everywhere with us doing a thousand miles in a week the length and breadth of UK! The Transalp was a comfy tourer but 1st gear was too high and it was plagued with silly little faults that were too annoying so I got rid about 8 months after buying it new shame but couldn't be arsed with the hassles

CB900- Now that was a bike, had a yank CB paint job and Yoshi tuned exhausts and other things, brutal in those days about 1983 ish did me first ton on it and learnt the art of going around bends I think it had 19" wheels front and back, you got the bend wrong you fell off or ended up in the hedge. None of the point and squirt of todays bikes were anyone with half a brain can ride them and cock up a bend and the bike almost sorts itself out!

Yamaha FJ1200- It was what I got after the Transalp it was the only transport we had at the time. It was happy to trundle around town and do the shopping as it was doing 150mph down the motorway, least that was what the clock said so there abouts! 

The XV750 bought it when it was only 6 months old with bugger all mileage on it, but a bit of a change from the CB900 but loved it and there she is all loaded up for a weeks holiday down in Cornwall! No hassles got 50 to the gallon no matter how it was ridden,  made the back rest and she had 4" overs on. The back rest was put on through necessity having already been down to Cornwall on a previous occasion and we stopped at Tintagel had a pint and a pie before setting off home, wife being slight tipsy nearly fell off several times nodding off to sleep! In those days there were not any bolt on custom stuff. we went to the HA kent custom show in 1984 on it had a wail of a time, remember going down the Mway and hearing a rumble behind looked in the mirrors and saw a massive dark blob and cars moving over left and right, as it got closer realised it was bikes so moved over myself and slowed down to get a better look, as they past I saw it was the Swedish chapter of HA's. as the last few past one of them waved us to join them at the back. Who am I to refuse that lot! Wife sat pillion giggling and I pretended to be tough haha! I think that was when I realised I had to have a Harley the rumble going right through your bones as they passed was a feeling I had to have.

Fitted new rear brake line with brake light banjo bolt, thought about mechanical brake light switch but looks a bit messy. Also when moving the bike noticed the risers seemed to move, on investigation threads knackered on one of them! Still good excuse to buy a new set of shiny risers (better that happened in the garage tho!)

Found an old foto of when I bought her back in 1997, a bit of a chrome barge. There were receipts for £2k worth of live to ride and chrome. I cant remember what attracted me I liked the colour but I swear I never noticed all the live to ride emblems which were stuck everywhere, until about a month after! I think that when you buy a Harley its the engine your buying into either it works for you or it dont and until they 

"rubberised" the engine each one was different.

Oil Tank

Fitted oil lines today... OK but look a bit tatty but will do to start up the engine, and make sure all is OK looking to use braided lines eventually, Cant get the rear OEM brake line to sit properly so have ordered braided one and brake light banjo to tidy it up.

Re aligned the rear muddy, mounted the brackets upside down!

fitted the oil tank and sorted rear exhaust bracket.

Just waiting for some 90 deg elbows to re route the oil lines over where the battery will sit.

Krome Werks pipes will stay as they are only a year old! But looking to have a 2 into 1 with old school trumpet silencer will be using a side mount no. plate which just needs slight modification because of muddy stay.

Almost there

View from the cockpit, Just the oil tank to fit and run the oil lines then the wiring.

The bars and that

Got the risers sorted and painted and back on the bike along with the handlebars, daft sod that I am forgot to thread the front brake master line through the yokes so will have to undo and re bleed ! still that can be done whilst the paint dries on the side mount number plate tomorrow !

Today I mostly.......

Made the axle adjusters, shortened the risers by an inch sanded and painted to match bars. drilled and prep'd the side mount no. plate. Dont plan to take rear wheel off twice so want all that lot sorted first.

AND dropped the bloody riser top whilst tacky , why o why do things have to land paint side down or even worse butter side down when you drop yer toast!

Hard Days work

Today I found out how hard Stainless is to drill! Don't have a drill or bit man enough to do the job! So plan two, ignore it and work on something else, something else... need paint -supplier doesn't have any left...Plan 3... sod it where's the beer!


Thanks for that Brushwarrior !

Rear end again

Made the Muddy struts today and fitted prior to painting next the axle adjusters! take it to bits paint and its done.

Small Adjustments

Front exhaust fitted, oil pipes and electrical wires zip tied under frame, rear muddy removed ready for new brackets. Need to locate some 10mm copper pipe to run oil lines from oil tank to pump so that it goes up and over the battery all a tight fit. So need it to look as clean as poss.

rear struts

Got a pair of rear struts made for the rear muddy today and started painting the levers chrome has had it, and sanded them down painted with smooth hammerite then will buff them so they are satin.

Rear Brakes

Result, managed to fit the OEM rear brake lines so now I can stop, ..........just need to start the engine now!!!!

foot rest

Nearside foot rest arrived from US today been looking for months for one cant find any in UK. need to sort rear wheel adjusters, then rear muddy and rear brake line.

front end this time

Head stock bearings turned up today, so got the front end back on, time to finish off the mounts for the switches so one needs one large helping of patience.
Success switches mounted neat and tidy might paint the mounts black to "loose" them in the bars. time to make the rear mudguard brackets and axle adjusters

that damn front end!

Today I started stripping down the front end to grease up and final assembly, another shot bearing.. forgot I needed to replace them so cant blame the old gal for that one!  also started sorting the switch gear but need a 3mm drill bit so that stopped that cos I cant be arsed to go to B&Q to pick up one

Bearings

Bearings turned up this morning so relented and returned to the back end! Besides beating seven bells outta the old ones is sure therapeutic! and installing the new races is equally so. Rear wheel back on and sorted just need to make the rear supports for the rear muddy.

That Backend again

Having sorted the rear caliper last night I thought I would fit all together! lined up things started shoving the axle through, wouldn't go???? the bearings had decided to fall apart well for goodness sake they are only 16yrs old !!!!!!!!!!!!!!! So I will re focus on the front end (that had new bearings 5K ago) cleaning and greasing and maybe's start on the bar switches

Parts

Parts so far aquired either from Lowbrow Customs, Ebay, Vintage chops or transferred from old bike and modified as and where

Old style seat & 3" springs, Biltwell weld on seat hinge

Oil Tank 9" x 5" round old skool style 

Pipe work for the rear hardtail

Biltwell bars

Speedo with built in LED idiot lights and trip counter  

Sparto rear light (reused)

Bates headlight (reused)

micro front and rear indicators (reused)

21" front wheel came off a wideglide laced with stainless spokes to a  Sporty hub and Avon Speedmaster tyre

Fork gaiters

Rear ribbed mudguard

OEM front and rear brakes and calipers modified
Dyna front master cylinder, smaller and neater than sportsters
set micro switches see links

Engine Mods

883cc to 1200cc conversion using J&E Billet pistons .005 over 

Crane N2 Cams

Crane Hi-4 single fire ignition

S&S Super E shorty carb with 1" manifold extension

Krome werks 2" AR drag pipes, (cos I bought em a year ago)

The Back End!

Spent the morning "adjusting" the rear calliper carrier, needed to shave off some metal top and bottom so that it fit between the rails and the fancy ribbing along the bottom pushed the carrier out from the frame which I hadn't noticed, and about 1/2" of the top so that the carrier will slide with the chain adjustment as the OEM setup.

The build

Pictures can be seen in the slide show which is easier than separate pictures I have found. Pulling the bike to bits was not a problem I have bolted on and taken off so many parts on this bike over the years as I messed about trying to find a design I liked. The main problem was when it was time to remove the back end of the frame ready for hardtailing by Twizzle down Dorsetshire way! I spent a long time on the internet looking at hardtailed sporties until I found what I wanted and took out the grinder.
Meanwhile, I joined the bike forums (at the top of the page) apart from the knowledge on these which was invaluable I also came across a community that had a genuine interest in shed builds as well as big bucks builds and no one was criticising unless you asked opinions.  

In the beginning

This is about the trails and tribulations of a first custom build Sporty built by myself with help from new found friends on a couple of forums (links on here) My Sporty has been in the family since 1997 when I bought the old gal as a bit of a chrome barge, it is my first and will be the last. When people say a Harley speaks to you they are right (at least pre 2K ones dunno about the new ones)I didn't need to ride it a press of the start button did it for me, the dealer not being a sole HD dealer thought I was slightly mad but I just knew. Over the years I have removed about £2K of chrome add ons and over the years bolted on many parts in my quest to find a style that I liked, I've joined and left many clubs as I am quite happy to ride on my own as and when I feel the need. My roots are in Easyrider like a lot of my generation, I was 12 when it came out but never saw it for years but the bikes, especially the Billy Bike was all I needed. My youth was totally obsessed with bikes, choppers in particular but life takes us on a funny path sometimes.Bikes sort of took a sabbatical until I turned 20. I then got back into bikes buying this and that jap stuff then turning 40 I said hang on I was going to own a Harley by now! And so old syd came into my life.I played around with styles and bolt ons but never was happy until I was reading Back Street Heroes 25th anniversary edition and they did a piece on 4 lads who called themselves the camsnappers the bikes were lean mean basic and narrow, which was just what I was looking for all these years so plans were set in place to build myself a basic narrow home grown sporty.