Build a Harley

[union]

Some of the parts started showing up yesterday.

UPS brought this to the shop from drag specialties.




In the smaller of the two boxes there was...
Fork bag for some storage
Passenger pegs to keep the wife happy
Slimline Jagg oil cooler
Dynojet power vision.



In the larger box was the Vance and Hines Big shot exhaust.







At home another box was waiting for me.

Plate relo kit. Since I'm going with a detachable sissy bar its one of those necessary evils. Of course my parts inspector had to make sure it passed his quality inspection as you can see.



My parts inspector





True track is currently in the mail. Should have that by the end of the week. Shocks have also been ordered. As long as they are in stock at ohlins I should also have those by the end of the week.

If everything comes in I'll be able complete the back end of the bike. If it all goes smooth I might have time to remeasure the bike and start to figure out the front end. We need to figure out wheel spacing with the new caliper setup, triple tree crown width, triple tree offset, and fork length. After that is figured out we need to design the triple tree and then get machine time to get it made plus a new axle, spacers, and a steering stem.

[Nny]

Kind of seems like you are going the same direction I have always wanted to with my StreetBob. Inverted forks, dual disc up front, raise the back end up a bit with better suspension. Maybe even find some mid controls that brought my feet back a little further.
The closest I came on research about the front end was that the Vrod lowers would slide on to the stock fork tubes on my StreetBob - giving me dual disc capability.
As far as the rear end went, I don't remember which model but the stock shocks on one of the touring bikes were about an inch taller and gave a much better ride and can be found for less than $100 off ebay.

Well, regardless it seems like you have a set path. Can't wait to see the finished product!!

[cdovego]

That's one cute pup.

[Garandman]

Kind of seems like you are going the same direction I have always wanted to with my StreetBob. Inverted forks, dual disc up front, raise the back end up a bit with better suspension. Maybe even find some mid controls that brought my feet back a little further.

I tried that with the Roadster: sought out a carb model. The engine cases are still very wide and the rear suspension travel is still short.

The Roadster came with twin discs and a tach along with XR length shocks. All I did to the forks was put a fork brace on and some update springs. I put Ricor shocks in the back. An illustrated summary:


Ricors.


The HD faithful completely ignored it and sport bike dudes went nuts over it.

[union]

Got another package today

This was inside.



In my research i couldn't find a definite answer whether the true track or sputhe was better. Both seemed to make each person happy with their purchase. I decided on the true track mainly because it was easier to order.

I was expecting the new shocks to be in today but sadly that didn't happen. Hopefully they are in tomorrow. I would like to be able to finish off the entire back end this weekend. If they don't show up I still have a lot of work I can do. Should be a good Saturday of bike modding.

I don't generally put out the invitation but if anyone is in the MA area and wants to come see what we do let me know. I'll send you the shop address. I think I'll be there most of the afternoon with what I plan to accomplish.

[SVRACER01]

a word of warning on the fork bag. ive seen them fuck up a lot of fenders.
youre gonna need a tuner for that exhaust. use Harleys super tuner. everything else sucks on HDs

[hawk]

a word of warning on the fork bag. ive seen them fuck up a lot of fenders.
youre gonna need a tuner for that exhaust. use Harleys super tuner. everything else sucks on HDs

I'm actually using the new FP3 from V and H and I like it. Works well and I havent had any issues. I'm using it on a 14 street glide.

In my research i couldn't find a definite answer whether the true track or sputhe was better. Both seemed to make each person happy with their purchase. I decided on the true track mainly because it was easier to order.

I was expecting the new shocks to be in today but sadly that didn't happen. Hopefully they are in tomorrow. I would like to be able to finish off the entire back end this weekend. If they don't show up I still have a lot of work I can do. Should be a good Saturday of bike modding.

I don't generally put out the invitation but if anyone is in the MA area and wants to come see what we do let me know. I'll send you the shop address. I think I'll be there most of the afternoon with what I plan to accomplish.

Let me know how you feel about the true track. I'm thinking about adding one to my glide this spring.

[union]

a word of warning on the fork bag. ive seen them fuck up a lot of fenders.
youre gonna need a tuner for that exhaust. use Harleys super tuner. everything else sucks on HDs

I'll keep an eye on the fork bag.

I have the dynojet power vision for a tuner. When the bike is ready I'll bring it Rob's dyno for a tune.

[SVRACER01]

I'm actually using the new FP3 from V and H and I like it. Works well and I havent had any issues. I'm using it on a 14 street glide.

my experience dictates otherwise.
vibrations tend to kill the aftermarket stuff prematurely. also, the ECM hates being lied to, which is pretty much what the the FP and PC do. they hook up inline between the wiring harness and the ECM and changes all the data blah blah blah.

super tuner is more like a key that allows you to unlock the ECM and change the map. then when youre done you lock it all back up and disconnect the super tuner. we have fixed a lot of running issues by just unplugging a PC or FP or other brand.

[SVRACER01]

I'll keep an eye on the fork bag.

bells too. if youre one of those people with a bell, DONT hang it off the lower triple or engine guard. its amazing how many fenders i see that have lost the fight with a tiny little bell

[tls25rs]

a word of warning on the fork bag. ive seen them fuck up a lot of fenders.

I'll keep an eye on the fork bag.

Might I suggest that when you discover where there may be any issue with interference or rubbing of the bag on the fender that you install a section of clear vinyl, like they use on the front of cars to help with the rock chips, between the bag and the fender. Then all you will have is a worn down piece of vinyl that you can remove and your fender paint will be blemish free underneath.

[Paul_E_D]

I knew this would devolve into a discussion of paint blemishes! I guess I'm a skeptic, but I really don't see the point of lavishing so much attention on this bike.

[OreoGaborio]

Says the guy with a track bike prettier than most riders street bikes

[union]

I know this bike isn't for everyone. I never thought I'd end up with a Harley but it was the only bike that fit my criteria I had for returning to street riding. Sportbikes were out. Too tempting to ride fast and too uncomfortable for long rides. I thought about a motard but way too tempting. I wanted something that I could bring the wife along. I also wanted something that had a lot of after market options.

When I first started looking at Harleys I went to Precision Harley in Pawtucket. One of the salesman came up to me and asked if he could help me. I said Yes I'm looking for a bike with no performance. At first he looked a bit shocked but after I explained my history and what I was looking for he told me I had come to right place. I ended up buying my bike somewhere else but here we are. I have a Harley to build up.

[nhbubba]

I love it. Totally understand where you are coming from. Following along.

The spoked wheels are awesome.

[cdovego]

I know this bike isn't for everyone. I never thought I'd end up with a Harley but it was the only bike that fit my criteria I had for returning to street riding. Sportbikes were out. Too tempting to ride fast and too uncomfortable for long rides. I thought about a motard but way too tempting. I wanted something that I could bring the wife along. I also wanted something that had a lot of after market options.

When I first started looking at Harleys I went to Precision Harley in Pawtucket. One of the salesman came up to me and asked if he could help me. I said Yes I'm looking for a bike with no performance. At first he looked a bit shocked but after I explained my history and what I was looking for he told me I had come to right place. I ended up buying my bike somewhere else but here we are. I have a Harley to build up.

I'd have a corvette or viper if I had any sense of restraint. I don't, it's sad. I get you.

[SVRACER01]

Might I suggest that when you discover where there may be any issue with interference or rubbing of the bag on the fender that you install a section of clear vinyl, like they use on the front of cars to help with the rock chips, between the bag and the fender. Then all you will have is a worn down piece of vinyl that you can remove and your fender paint will be blemish free underneath.

im sorry, i wasnt being clear enough. when i meant fuck up a fender i mean dents...large dents. ive seen a fork bag with nothing but a pair of sunglasses in it cave in a fender.

[tls25rs]

im sorry, i wasnt being clear enough. when i meant fuck up a fender i mean dents...large dents. ive seen a fork bag with nothing but a pair of sunglasses in it cave in a fender.

In that case I might suggest finding a bike where the manufacturer didn't cheap out on the front fender materials. However this bike meets the stated needs of the OP so that idea is out. Guess he'll just have to be careful with it.

[union]

Got a bunch done this weekend. Unfortunately the shocks haven't arrived yet so I didn't get done what I had planned.

Bike on the lift and ready for some work





Started by taking off things that were going to be in the way. Exhaust, front fender, and seat went.





Started with the True Track install




Giving the engine some support.



Front installed. Went pretty easy.



Had an interesting issue with the rear. The bolts they supplied were button heads and didn't sit flush on the brace.



It was an easy fix. Just walked over to the hardware store and bought a couple of socket cap bolts and things went on nice and easy.




With the true track installed I decided to tackle the detachable docking hardware, turn signal relo and the plate relo. Took the rear wheel off to make it easier to get to the wiring.




Stock setup



The plate relo kit and docking hardware was nice and simple.

Had to change out the inner bracket to one with threads for the docking hardware and the turn signal stalks.



The plate relo bracket popped in easy and plug directly to the stock harness.

This is where I just don't get why Harley does some things the way they do. The turn signal relo instructions have you cut and splice three wires on each side. They wires are run through the turn signal stalks so they are not exposed

In an effort to not have six spliced wires under the rear fender I decided to pick the stock connectors and rewire the signals so they had no splices in them.





Rerouted the wires the way they went from the factory and plugged them back into the main harness. I wish I could say this was quick and easy but it wasn't Took me a few hours to pick the wires, put new connectors on the wire ends (luckily they came with the plate relo kit but should have come with the signal kit) and get the end back into the harness.





Rear complete



Next I was going to do the passenger peg mounts.



Unfortunately one the threads galled up a bit and I didn't have the right sized thread chaser to fix it so I'll tackle that hopefully next weekend.



Last thing I did this weekend was route the wire for the power vision. Pretty easy to do.

Plugs into the grey plug



Out through the fuse box.



Left to do when I have more time next weekend is lift the tank and run the wire up to the bars.

Also prepped the new exhaust so its a quicker install after I get the shocks on and remeasure the bike with the computrack machine.



Hopefully the shocks show up this week and after next weekend the bike will be road worthy. After I get the measurement with the new shocks I'll be able to start to figure out the front end and what I need to complete it.

[union]

Got a bit more done on the bike today. Not everything I wanted to but a decent amount.

Started with different pegs. Every bike needs an imperfection somewhere or it will find a way to get one. I had these pegs laying around for about 10 years now. I thought they looked good and I liked the style. After about 10 years of sitting in the basement the chrome has started to peel but its perfect.





Next on the list was the new exhaust.

Vance and Hines uses their own exhaust bracket so the stock one had to go.



It required me to remove studs in the transmission bearing housing. I was pleasently surprised that Harley set the studs up with a way to removed them with a socket easily.



If you're not presented with such an obvious way another way you can removed a stud is with two nuts back to back.



New exhaust bracket installed.



Old gaskets out.



New ones in.



Pipes ready for the heat shield.



Heat shields loosely installed.



Pipes on the bike.



2 minute video comparing stock pipes to the big shots.

https://youtu.be/5X4zQ5n13nY

Replaced to crappy stock grips with a set that should be easier on the hands.



I started to mock up the new front end.

This is a pair of clamps we had made for supermoto racing and they just happen to be the correct diameters for the forks I plan to use.



Forks in the clamps. This will give you an idea of what it will looks like when the front end is complete.



Unfortunately I had to stop there. The crown width of the clamps is nit wide enough to fit the Harley hub. I will have to come up with a different way to figure out my spacing.

[Sheppo]

One thing I like is the amount of detail and pictures you put in your 'build' threads. I like how this is going.

[union]

Not a lot to show but a few things have arrived. Most notably is the new brake calipers. Should have some good brakes once the front end is completed.



No photos but I can get some if people are interested. Ordered a garage door opener from Mo-door.com. Was pretty easy to program. Just need to figure out where to put it on the bike.

The gps unit should arrive today. Now I can go out, get lost riding around and hopefully find my way home at the end of the day. Ended up going with the Garmin Zump 590 LM. Luckily my work partners with Garmin so it was affordable.

[zombie]

Looking real nice so far

[union]

I didn't get too much done this weekend being a holiday weekend and all. Had to do the domestic thing. I did manage to install a new over the range microwave.

As far as the bike is concerned. I wanted to tackle the wiring but I don't think that is going to happen until I burn off a tank of fuel. I asked the dealer to not put gas in it but they insisted. I want to lift the tank to run the wires for my power vision and gps.

I did manage to mock up the new front end a bit. I wanted to be sure my idea was going to work before I went too far. It all fit pretty good. I just need to come up with some spacers for the axle and I think I might space out the rotors a little bit so the front end doesn't look too narrow.

Here's the quick mock up.



My biggest concern was whether or not the different caliper would line up with the rotor and not hit the spokes. Sometimes that is a bit of an issue with supermoto bikes. Here it wasn't an issue at all. Everything cleared with plenty of room.

[catch2otwo]

That is going to look mighty slick