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JaySco
08-07-2009, 3:47 AM
I got my frame back yesterday so this project is officialy underway!! I had it hardtailed by Elswick Cycles, can't say enough about Robert, work is top notch, prices are better than most anywhere, and good customer service too. Back to the bike, 4" stretch and 2" drop.
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3039.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3040.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3041.jpg

As you can see the major fab work I had done, I don't have the skill or the know how to pull off work like that. But I will be fabbing up all the little BS like fender mounts/struts, plate bracket, etc. I'm planning on using the stock wire loom, after I strip about 4 miles of wire out of it. Progress will be slow because I'm usually in the garage for about 5 minutes at a time, thats when the kids or the wife come in to distract me with something else.
I've got a box o' parts being shipped right now, got a few parts allready in the garage, and got a few things I still need to order. Expect lots of questions.

willythepirate
08-07-2009, 6:20 AM
Looks like a good start man. Where in cali are you?

JaySco
08-07-2009, 6:46 AM
Im in Rialto, but nobody ever knows where that is, by Fontana. Southern Cali

captainawesome
08-07-2009, 7:55 AM
you will spend more time ripping the stock harness to shreds than actually just making your own harness. study up on diagrams and go for it.

the tail looks good too.

imtheslime
08-07-2009, 8:57 AM
Nice! Just emailed him the other day about one for my Ironhead.

Kokuma
08-07-2009, 10:50 AM
Lookin' really good, man. I love the chop sporties. Its gonna be wicked quick too with all the weight taken off! I got a similar build going on. Check it out on my profile. Maybe we can talk shop.

Kokuma
08-07-2009, 10:52 AM
I agree. Way too many wires for such a "small" bike. One could run an in-dash entertainment system with all the wires coming out of it!

theOldePro
08-10-2009, 11:36 PM
Robert at Elswick Cycles is awesome. Just contacted him about a weld on for my bike as well. My question is, how do you determine how much stretch to go with. Obviously, the longer will get a clean straight line down the entire backbone of the bike, but on some bikes the stretch can look a little "weird".

I'm thinking somewhere between 2-4" of stretch, but again, what's the real difference? Is there a stock wheelbase that the classic hardtail frames had?

superflysnow
08-11-2009, 2:20 AM
man same here, just emailed him tonight... I have seen a bunch of +4" that have looked pretty good, not sure about the drop though. anyone done a 6"? i know most dont like em, but +6" on a Trump looks real good to me!

nickle
08-11-2009, 3:32 AM
It depends on your goal. Building a longbike? If not, I prefer a shorter wheelbase.

WhiteFox
08-11-2009, 8:32 AM
you will spend more time ripping the stock harness to shreds than actually just making your own harness. study up on diagrams and go for it.

the tail looks good too.

I disagree, I ripped out my speedo and turn signals, there is a bunch of wires, but as I was doing it I thought I could just start from scratch. Yeah right, that would have been 5x more work. It's much easier to pull out what you don't want. And if you have problems in the future it'll be much easier to trace the stock wires than ones you've built.

superflysnow
08-11-2009, 11:41 AM
Looks good! that tail looks like it will work out really nice...

do you have any close ups of the oil tank? how is it mounted... other than the obvious, do you have spacers cut for it or is it rigid mounted against the frame rails?

Binky
08-11-2009, 3:19 PM
The frame looks hella tough..

JaySco
08-11-2009, 4:10 PM
Robert at Elswick Cycles is awesome. Just contacted him about a weld on for my bike as well. My question is, how do you determine how much stretch to go with. Obviously, the longer will get a clean straight line down the entire backbone of the bike, but on some bikes the stretch can look a little "weird".

I'm thinking somewhere between 2-4" of stretch, but again, what's the real difference? Is there a stock wheelbase that the classic hardtail frames had?

I looked at what was already on the market, the KK hardtails as well as a couple other cheaper ones have a 2" stretch, they looked a little on the stubby side to me. I saw a couple custom rears with a 5"-6" stretch and they looked too odd and empty in the rear. I like the overall look that the Led Sled gives and they advertise as 4" stretch and 2" drop.
There has been great discussion over where all these measurements are based on, rake, downtube stretch, backbone stretch, blah blah. When I told Robert what I wanted I told him based off the frame in front of us. I left the swingarm on and told him I want it to sit 2" lower and 4" back. He had a frame there that had 3" of stretch, but like you said the backbone wasn't perfectly straight all the way down.

JaySco
08-11-2009, 4:16 PM
I disagree, I ripped out my speedo and turn signals, there is a bunch of wires, but as I was doing it I thought I could just start from scratch. Yeah right, that would have been 5x more work. It's much easier to pull out what you don't want. And if you have problems in the future it'll be much easier to trace the stock wires than ones you've built.

I think I'm going to go with you there. I made a harness out of scratch on my last bike only becuse there was nothing there to start with. I kind of like the idea of keeping what little I'm going to have left with color coded wires and factory harnesses. I plan on just stripping/shortening/lengthening where needed.

JaySco
08-13-2009, 5:40 AM
Finally got a minute to work on this thing. All the seat mounting hardware came in, so I got that part done. I know it ain't much, but baby steps are better than just sitting in the garage looking at it.
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3156.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3158.jpg

Hinge from Bitwell (of course).

Idnthv1
08-13-2009, 9:34 AM
Lookin good so far...keep the updates coming.

Heis
08-13-2009, 9:54 AM
looking good so far. How much of a complete bike did you get when you purchased it?

BolliverShagnasty
08-13-2009, 10:41 AM
Awesome. I can't wait to weld a proper hardtail on my sporty.

superflysnow
08-13-2009, 11:27 AM
man i am super exited to see this thing come together... looks like a redtailleather seat? I have also decided on the same rear end for mine so I will be watching closely!
-josh

JaySco
08-13-2009, 5:37 PM
looking good so far. How much of a complete bike did you get when you purchased it?

Thanks. I don't think I get what your asking. It was a complete stock bike a month ago.
Superfly, good eye on the Red Tail seat. It cost more than what I had planned for the seat budget (I'm just a cheap bastard), but well worth it. Very quality work and a nice piece!
Good news and bad news, I have worked all of 3 months this year, and will be off again in Sept, thats the bad news. Good news is I have all the parts I need to finish this project, so in Sept I'll have the time. So expect a flood of progress pics then.

JaySco
08-14-2009, 5:26 PM
Got another piece worked on last night. The fender was a little big for the tire so I wanted to form it a little better. Before and after pics:

http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3153.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3159.jpg

I brought the ends together about 1 1/2" . I just used heat to bend it so of course it rippled down the sides in a few places. I got pissed because I knew the right way to do it but tried to half-ass it anyway. After a cooling off period (for me and the fender), I heated the rippled spots and tried to beat them sraight again.....it worked pretty good!! It's pretty smoothed out overall, there is still a spot or two that can use some detail work, but other that that I'm happy with the results. I still haven't decided how much of the fender I'm going to use, somewhere in the 1/2 to 3/4 range. I think after I get the motor in I'll get a better idea of the look I want.

SDJose
08-14-2009, 5:58 PM
Nice hardtail. Looking forward to watching the progress.

davem
08-17-2009, 2:14 PM
Lookin great!
About to hardtail my sporty over here in blighty not stretching just going old skool bobber and was wondering if there would be enough room at bottom for battery so you've done me a favour!

JaySco
08-24-2009, 12:13 PM
No real progress yet, but at least it's not just an idle project. I got the motor in to line some stuff up, and to make things go faster once my chain coversion arrives, and got my fender cut to where I want it. I'm going to go with the strutless fender idea and reinfoce the inside with either the cut-off piece or some flat stock. I'm going to take this time to fab up a coil bracket, it will be where the choke was, I might incorperate the choke in somehow, or might move it by the carb, still undecided on that, and now's a good time to start on the wiring mess.
I have a deadline!! I want to have this thing on the road by the end of Sept.! It won't be totally "done", but road worthy anyway. I have sept off, but will back to work in october. So after a one month shakedown, I can strip it down and make changes (if need be) and paint in Oct..

Cut off fender (still going to shape a little more)
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3170.jpg

And motor back in (for now)
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3171.jpg

JaySco
08-27-2009, 4:57 PM
Almost done!!
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3174.jpg




Yeah right. This is just a rough draft, I wanted to see how some things would line up and look changed around, but I needed to make sure it would all fit. I like 'under construction' pics almost as finished bikes, I thought you might too.

I'd like opinions on paint. I was going to do a two tone scheme with dark blue and cream colors. But since my tank is almost flawless I was thinking of getting paint that matches the factory blue and doing the fender and oil tank in that color. I think the dk blue/cream would be classier, but I think all factory blue would look racier and make the details of the bike stick out more than the paint......whadda you think????

theOldePro
08-27-2009, 5:04 PM
the beauty of the paint is that you can always change it up.....if you're liking your blue tank, match the fender for now. It would probably be a nice thing to practice your paint skills on as well starting with the fender rather than stripping your tank and starting over with that.

mplsdave
08-30-2009, 8:26 AM
diggin those bars

BryanEOD
08-30-2009, 12:12 PM
looks like your project is starting to shape up... As somebody said earlier I dig those bars as well...

Jackieshan
09-01-2009, 5:57 PM
Yeah... nice bars! They look familiar. I gotta agree with whitefox on the wiring. I cut out about 10 lbs. of stock wiring on my bike... seriously. And it was a whole lot easier than making my own. Especially when the ignition wires and regulator wires have those nifty little plugs you can use. Most of the visible wires I replaced with some cloth covered stuff I found online. Plus I've heard the cheap stock ignition module craps out if you don't do it right. I don't know if that's true, but I've seen it happen on two bikes. Could be a coincidence. Has anyone else heard of that?

JaySco
09-02-2009, 12:48 PM
Yeah Jakie, I know I've seen those bars somewhere before, just cant place it (you got nice un's too!). I got the bars from the same place as the hardtail, Elswick Cycles. And same as the rest of the stuff, I'm totally happy with the bars. Anywho, not a whole lot of progress but moving forward slowly is still moving forward...just slowly. I'll pass posting all the before pics because most people know what the before product looks like anyway, and it just slows the pics for folks still on dialup. So I decided that the top motor mount is the spot that I want the coil to be. I gave it an inch or two of clearance just because a unit that makes spark that close to a unit that flows fuel still makes me somewhat uneasy. But I kind of like the final result, far enough to make me feel safe(er) and looks symetrical to the other side with the air cleaner. What do you think?
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3192.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3191.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3190.jpg

Also got my starter plunger on (on the starter), and got the chain conversion sprokets in place.
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3193.jpg

Jackieshan
09-02-2009, 3:07 PM
I had Jay at special 79 make mine. I thought they turned out perfect. Not too many people I trust when it comes to welded bars. I love the feel riding too. I've heard good things about Elswick. Is that where you got the chain conversion? I need to do that on mine. My back tire is so close. I even think it rubs a little at high altitudes. Bikes looking sweet by the way.

JaySco
09-02-2009, 3:34 PM
I haven't rode with any like this yet, but they looked right for me, still enough leverage to retain control, yet not so wide that your arms are flapping in the wind. After getting work done at Elswick's, I wouldn't go anywhere else for any product that they make, but the chain conversion is made by Baker and I just got it off some random internet shop. For what the no-name brands are going for, I couldn't justify not dropping the $20 more and getting the Baker brand. I haven't fitted the chain yet but at 120 links it should be long enough to give a little extra room.

JaySco
09-03-2009, 6:11 PM
I made up a little box for the electrics today. Even though I'm running the bare minimum I still had a few things that needed a spot (breaker, ignition switch, hi/low headlight switch), and I couldn't figure a good spot to hide it all, so I made a little box to sit in between the oil tank and the frame. I was going to make it fully enclosed but figured that everything was exposed to the elements when the bike was in stock form, so it should still be ok with an open top box. Here it is......
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3194.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3195.jpg
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3198.jpg
And it will sit off the tank and frame about 3/4", attatched from the top of the frame like so....
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3197.jpg

I know it looks pretty crappy right now. I still have to grind a little more, and I might fill the cracks with body filler or JBweld to smooth it out a little more. It's the first piece I've fabricated, and I didn't throw it at the garage wall 20 times, so I'm pretty happy about it.

MrCrown
09-03-2009, 7:00 PM
looks good!!! how are you mounting the electrical box to the frame? welded to the frame?

keep up the good work...really inspires me to get back to the shop...ugh.

JaySco
09-03-2009, 7:18 PM
I haven't decided if I want to weld tabs on top and mount it to the rails under the seat, or if I want to weld bungs onto the back of the seat post and bolt it through the front of the box. I havent thought that far ahead yet.
LIke I said, this is the first piece I fabricated (can you tell?), so I can't wait to make more shizzle.

imtheslime
09-08-2009, 8:49 PM
Damn, you got some momentum going on this build. Look-n-good.

JaySco
09-09-2009, 1:11 PM
Damn, you got some momentum going on this build. Look-n-good.

Thanks, I ordered all the need parts the last 2 months, and I'm off this month, so I try to get something done daily. Here's a couple more progress pics for today:
Got the electrical box mounted, Note that the mounts arent that conspicuous, I just took the pic at an odd angle to show how I did it
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3206.jpg

View from the top, under the seat. Still need to drill another hole on the opposite side for the hi/low switch once it comes
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3207.jpg

Should have the fender mounted tomarrow. For now I got the bungs in place on the fender and mounted the lower strut mounts
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3208.jpg

The lowers look a little big in the pics, I think once everything is painted and they are hidden somewhat by the struts they will be less noticable. I used a chain link from a machine at work, cut in half, and welded the 5/16" nuts in place (welded on the backs)
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3202.jpg

JaySco
09-16-2009, 3:58 PM
Got some more done. I got the fender mounted, the bottom of the fender was still a little tweaked and I couldn't get it straight, and I didn't want to run with any bulky fender mounting system so I cut a little more off. Still more fender there than what some of you run with. And I decided to stick with the factory blue, even though the one can of matching paint was $50 fricken bucks from Colorrite!!!!!!! Here's where I'm at now:
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3219.jpg

Still need to run the rear brake hose and go through the wires. Hope to be back on the road in about 2 weeks.

MrCrown
09-16-2009, 5:16 PM
looks good!!!

mplsdave
09-16-2009, 8:00 PM
thats awesome. what blue is that?

JaySco
09-17-2009, 7:45 AM
Thanks. The paint is called Impact Blue Pearl, it's the factory paint on the tank then I got a rattle can to match the other pieces. http://www.colorrite.com/product/harleydavidson-impact-blue-pearl-2005.cfm

mplsdave
09-17-2009, 1:02 PM
wow thats a good match for some rattle can! im excited to see pics of it on the road!

JaySco
10-13-2009, 5:35 PM
I haven't posted in a while but I've still been makng progress. I won't bore you with pics of the wiring and little knick-knacks. Here's a pic how it is now
http://i119.photobucket.com/albums/o131/jay_sco/Sportster/IMG_3323.jpg

All I have to do is put in brake fluid/bleed brakes, and put on a chain. Thats how it's been for two weeks now, but I'm flat busted on the cash situation, should be another week and I'll be on the road.

mplsdave
10-13-2009, 5:52 PM
looks awesome! still cant wait to see pics on the road... or even vids!

MDRide
10-14-2009, 9:01 AM
Looks good. I did not think the blee tank would look right when you said it would be painted but I was wrong. It works.

dso
10-14-2009, 10:30 AM
Bike looks awesome man, great build and thanks for the comments regarding the direction of my build and stretch of the hardtail. Would love to see more pics when you get a chance too!

SportsterBob
10-16-2009, 10:56 AM
this project is premium!
gratulations! perfect!

superflysnow
10-20-2009, 8:52 PM
hows it coming?
got it on the groud yet? the suspense in killing me!