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ManicMechanic
07-16-2014, 8:11 AM
Bought a sporty to get around town.

The obligatory "before" shot of the bike. It was a really nice, clean, tidy bike but I just can't leave things alone. For better or for worse.....

The day I picked her up.


http://i902.photobucket.com/albums/ac223/1216dan/46Q9BnU_zps80639e10.jpg


http://i902.photobucket.com/albums/ac223/1216dan/Gs1IX2m_zps3a395f30.jpg

ManicMechanic
07-16-2014, 8:13 AM
The stock tank is huge so went with an earlier one and got rid of the front fender.


http://i902.photobucket.com/albums/ac223/1216dan/20140515_195800_zps4e491388.jpg




http://i902.photobucket.com/albums/ac223/1216dan/20140518_203731_zps4039f0e6.jpg

ManicMechanic
07-16-2014, 8:19 AM
Some H bars.

http://i902.photobucket.com/albums/ac223/1216dan/20140715_183059_zpsfbdbd0d4.jpg


http://i902.photobucket.com/albums/ac223/1216dan/20140715_183122_zps18efcd92.jpg

ManicMechanic
07-16-2014, 8:25 AM
Made and welded up a solo seat bracket. I've only got a shitty buzz box to the welds aren't the prettiest but it does the job.


http://i902.photobucket.com/albums/ac223/1216dan/20140715_182945_zpsed683113.jpg


http://i902.photobucket.com/albums/ac223/1216dan/20140715_183028_zpsb872711f.jpg

ManicMechanic
07-16-2014, 8:30 AM
Fitted some shocks from a superlow and lowered the whole thing plus did a rear fender chop.


http://i902.photobucket.com/albums/ac223/1216dan/409e6a20-e811-4686-adff-26782d3608de_zps246e5226.jpg


http://i902.photobucket.com/albums/ac223/1216dan/20140707_171802_zps00a8d04f.jpg

ManicMechanic
07-16-2014, 8:40 AM
Shaped the fender and made a temporary number plate mount/light.

http://i902.photobucket.com/albums/ac223/1216dan/20140709_205203sdfsdfd_zps7edf25aa.jpg


http://i902.photobucket.com/albums/ac223/1216dan/20140715_183157_zps5784693d.jpg

ManicMechanic
07-16-2014, 8:49 AM
Thinking about adding a sissy bar.

Thoughts on sissy bar? Yes/No?


http://i902.photobucket.com/albums/ac223/1216dan/h_zps4e367171.jpg

DaNgER556
07-16-2014, 8:53 AM
Looks good. Youre right about it being super clean stock. It looks way better now though. I hate that newer huge tanks

nofendertom
07-16-2014, 9:57 AM
is your rear tire mounted backwards- wrong directional rotation?

DeadSeaGulls
07-16-2014, 12:49 PM
Thinking about adding a sissy bar.

Thoughts on sissy bar? Yes/No?


if I were to put a sissy bar on a sporty i'd probably try to match the angle of the front forks, not the frame.

Motorradfahrer
07-16-2014, 12:56 PM
if I were to put a sissy bar on a sporty i'd probably try to match the angle of the front forks, not the frame.

Good looking bike you have there. I agree with DeadSeaGulls; keep the angle of the sissy bar matching that of the front forks.

ManicMechanic
07-16-2014, 2:33 PM
is your rear tire mounted backwards- wrong directional rotation?

Cheers.

Good spot...The tyre is mounted backwards. I'm guessing when the PO had it mounted he went to a non Harley shop and seeing as most of the Jap stuff has the drive on the left, they took that as a reference and mounted it the wrong way round.

ManicMechanic
07-16-2014, 2:36 PM
Good looking bike you have there. I agree with DeadSeaGulls; keep the angle of the sissy bar matching that of the front forks.

Yeah, I see what you guys mean.

I just cant decide if I should have one on there or not.

DeadSeaGulls
07-16-2014, 3:58 PM
Yeah, I see what you guys mean.

I just cant decide if I should have one on there or not.

I'm all about sissy bars, but I do a lot of camping. Strapping my hiking pack to my bike, riding for hours on some scenic byway, then onto some dirt roads, until I'm in the boonies. Seen my buddies backpacks and hiking packs shift around and fall off or rub on the rear tire too many times for me to not want something sturdy to strap to.

Also, a few years back a lady in her 50's came up to me and said "My mother told me that you can tell how much a man loves his woman by how tall his sissy bar is, and you sir must be a real casanova". My sissy bar on that bike was pretty tall.

ManicMechanic
12-26-2014, 11:42 AM
This is where I left things off. Rode the bike like this all summer.....

http://i902.photobucket.com/albums/ac223/1216dan/IMG_20140817_235313_zps617a6dfa.jpg







Made little changes along the way. Got rid of the air cleaner assembly and a new rear tyre went on.

http://i902.photobucket.com/albums/ac223/1216dan/20141115_1446156_zpsd4840452.jpg

ManicMechanic
12-26-2014, 11:44 AM
Got some time off but its freezing in the garage so......brought the bike in. :D

http://i902.photobucket.com/albums/ac223/1216dan/20141219_164326_LLS_zpsef1c58f2.jpg

ManicMechanic
12-26-2014, 11:46 AM
Bars narrowed and all switchgear and original levers binned.

http://i902.photobucket.com/albums/ac223/1216dan/20141225_202113_zps9fa2011b.jpg

ManicMechanic
12-26-2014, 11:48 AM
Forks lowered roughly 2.5 inches. All the seals were rotten and the oil had turned into sludge.

http://i902.photobucket.com/albums/ac223/1216dan/20141223_123731_zps4eeb747c.jpg

ManicMechanic
12-26-2014, 11:55 AM
Yokes taken off and drilled for new headlight mounts. All wiring got stripped out as well.


http://i902.photobucket.com/albums/ac223/1216dan/20141224_172353_zpsf135f493.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20141224_172422_zps9fa698c5.jpg

ManicMechanic
12-26-2014, 11:57 AM
The cutting disc broke so will have to chop the rear of the frame at a later date.



http://i902.photobucket.com/albums/ac223/1216dan/20141226_150044_zpsfa2ffb98.jpg




http://i902.photobucket.com/albums/ac223/1216dan/20141226_150203_zps5e7bed46.jpg

ManicMechanic
12-26-2014, 11:58 AM
Time to sort out a new loom.

http://i902.photobucket.com/albums/ac223/1216dan/20141225_201959_zps877c91e4.jpg

BrokenSprocketGarage
12-26-2014, 6:29 PM
Front forks look cool. Really changes the look and stance.
Sporty wiring is my specialty, if you run into any problems I'd be happy to help!

haizenberg
12-27-2014, 8:15 AM
I like the couch. So you drink beers and watch her to think about how you'll do it haha

ManicMechanic
12-27-2014, 10:19 AM
Front forks look cool. Really changes the look and stance.
Sporty wiring is my specialty, if you run into any problems I'd be happy to help!

Thanks. I'll keep it in mind.






I like the couch. So you drink beers and watch her to think about how you'll do it haha

Correctamundo! Living the dream. :cheersmate:

paulw
12-28-2014, 1:41 PM
where did you get that clutch lever?

ManicMechanic
12-29-2014, 12:43 PM
where did you get that clutch lever?

Ebay. It's some generic assembly for earlier models.

ManicMechanic
01-04-2015, 2:43 PM
I've run out of time to do a dry build before painting so I'm doing it all in one go , two steps forwards one step back......:banghead:



http://i902.photobucket.com/albums/ac223/1216dan/IMG_6475_zps17ddf46f.jpg




http://i902.photobucket.com/albums/ac223/1216dan/IMG_6470_zps3cd87b78.jpg




http://i902.photobucket.com/albums/ac223/1216dan/IMG_6472_zps2928ad1a.jpg




Waiting on the cutting disc so I can chop the frame rails and mount the wheel.

ManicMechanic
01-11-2015, 9:44 AM
Frame chopped and back on two wheels.



http://i902.photobucket.com/albums/ac223/1216dan/20150111_143639_zps6cacd0f8.jpg

Motorradfahrer
01-12-2015, 11:22 AM
Bike looks good. You may want to cut/shorten the bottom of the fork covers by an inch or so to get them to line up with the legs.

ManicMechanic
01-13-2015, 1:31 PM
Bike looks good. You may want to cut/shorten the bottom of the fork covers by an inch or so to get them to line up with the legs.

Yeah, I though of doing that but to me the shrouds/covers look a bit off when they are cut short. Plan is to ride it like this over summer then build a gradient on the lower fork in aluminium so there is a transition without shortening the shrouds.

ManicMechanic
04-19-2015, 1:20 PM
Got a bit more done.

Converted from electronic ignition to points. I wanted to get rid of the VOES and simplify everything. Started on the wiring. Ignition wiring is done and the bike fired up, just need to finish all the rest of the stuff ie lights, horn etc.

http://i902.photobucket.com/albums/ac223/1216dan/20150418_170014_zpspkx5bxiz.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20150418_170055_zps9hfbflni.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20150418_170127_zpslu9msn4l.jpg

ManicMechanic
04-19-2015, 1:41 PM
Here is a video of it running.



http://vid902.photobucket.com/albums/ac223/1216dan/VID_23990313_221920_zps5bsg7mmy.mp4

Ninskrilla
04-20-2015, 10:13 PM
Are those biltwell bars?

tcainer
04-21-2015, 9:53 AM
Always love watching people tear apart their bike and put it back together so quickly. I'm jealous of that ability. Bike looks killer, man.

brooklynbomber
04-22-2015, 7:03 AM
Got a bit more done.

Converted from electronic ignition to points. I wanted to get rid of the VOES and simplify everything. Started on the wiring. Ignition wiring is done and the bike fired up, just need to finish all the rest of the stuff ie lights, horn etc

Any reason you went this route? Points are so finicky compared to the rest of the bulletproof stuff you got going on with this bike.

ManicMechanic
04-23-2015, 12:12 PM
Are those biltwell bars?

They are custom made.



tcainer
Always love watching people tear apart their bike and put it back together so quickly. I'm jealous of that ability. Bike looks killer, man.

Its still far from being ready but cheers. Appreciate it. :cheersmate:



Any reason you went this route? Points are so finicky compared to the rest of the bulletproof stuff you got going on with this bike.

There are a few reason...I suspected the VOES wasn't working correctly...and I wanted to get rid of it anyway. I'm thinking of replacing the tank for something a little smaller in the future and wanted to clear all the clutter. Point ignition also means less wiring, which is always a good thing in my books plus I liked the idea of having mechanical ignition in keeping with the bare bones / simple build.

I've herd both good and bad things about them. Some love them for their simplicity and troubleshooting advantages.....others avoid them like the plague.

I decided to try it and make my own mind up. I don't mind the idea of checking them every couple of thousand miles.

ManicMechanic
05-17-2015, 3:09 PM
The wiring is all done. It took a while but I wanted to do it properly with soldered connections and proper automotive connections blocks all wrapped in cloth tape.
I've tried to keep it as modular as possible to allow me to add/remove things in the future without having to splice the loom.

The sun was shinning, which is a rare occurrence so I decided to take it for a quick spin (closed road section) to see how it was running. The result........its never ran this good. I've drilled the slide and shimmed the needle as well.

I will do a better video of it running/riding at a later date.

Oh...and I've also christened it "Nippon Sportster" as a homage to the Japanese styling cues.

Things left to do...


Source and mount a rear fender.
Make and install licence plate bracket and rear light.
Modify/make a new exhaust with baffles as its a bit too loud for regular city use.
Source and install a new front brake master cylinder and remount the front brake calliper.
Paint the tank.





https://www.youtube.com/watch?v=INzN070LPgU

ManicMechanic
05-30-2015, 9:09 AM
Got a bit more done.

2 inch exhaust manifold with baffles, replaced the original.

I couldn't source a rear fender that I liked so I masked off the original and cut it down.

Opinions on the rear fender? I cant decide if I'm happy with it or not.


http://i902.photobucket.com/albums/ac223/1216dan/20150530_151908_zps3niqxhfg.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20150530_151923_zps0rtguv40.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20150530_152110_zpspwfch5uv.jpg



http://i902.photobucket.com/albums/ac223/1216dan/20150530_151941_zpssxauujnd.jpg

nofendertom
05-30-2015, 7:55 PM
I like the rear fender---maybe round off the corners a little to lose the cut off fender look---might make it
look a little cleaner---my .02 cents.

tjgonz
05-30-2015, 9:43 PM
Opinions on the rear fender?

Love the build! Almost went this route but I strap a lot of shit to my bike.
My opinion is I can see this working well & at $20 on the ebay Id grab it & boom, done.
Cheers brotha!:cheersmate:

http://i56.photobucket.com/albums/g177/tjizzle2da/T2eC16JHJHMFHh2So8BR1mvBy0g--60_12_zpsa4870fyz.jpg

ManicMechanic
06-01-2015, 12:51 PM
Cheers for the feedback :cheersmate:

Going to try and shape the rear of the fender as suggested and see how that works out.

Fseco
06-10-2015, 4:05 PM
Give us more about your bike, really dig it

ManicMechanic
06-13-2015, 8:51 AM
Made some progress...

I couldn't find a side plate mount and light combo that I liked. Most of them mount to the axle or position it out too wide. So I got some bar stock and made my own mount etc.

Picked up a sportsbike front master cylinder drilled it for the 1 inch bars.

Even managed to find the time to put some decals on the tank because I was getting a tired of people asking what it was. :banghead:

Took it for its test and it passed and is now road legal.

It seems to be getting a lot of attention when its parked up with people saying things like.

"That's a real Harley isn't it?"

"I can tell that its the original old Harley. Was is expensive?"

"That's the real deal. I used you have one too"

"I really like this shovelhead"

"Dude that thing is legit"

:confused:

Things left to do are paint it and shape the rear fender but the sun is out and the bike is road legal so I doubt it I'll get around to it any time soon.

Way too much fun riding.........runs like a an absolute dream.

Cheers.



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%201_zpsbtg3vc5q.jpg



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%205_zpsacrdl17b.jpg



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%203_zpslgrmmplm.jpg



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%204_zpsiqvzcwqz.jpg



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%202_zpsp7xwi4w7.jpg



http://i902.photobucket.com/albums/ac223/1216dan/Nippon%20Sportster%206_zpsypvi787d.jpg

nofendertom
06-13-2015, 10:04 PM
I like the way your bike looks---you did a good job---plate holder looks good (you guys sure have a big ass plate)---so simple to make
and cheap too---you didn't ask but---I would cut about an inch off that break lever so it is shorter than the grip and finish it off so it looks
like it came that way---also if you got some clear reinforced fuel line for your brake reservoir you could shorten the length that you have
and be able to see the amount of fluid that you have in it so you could adjust the amount as your brake pads wear---just my .02 cents.

ManicMechanic
06-14-2015, 8:41 AM
[QUOTE=nofendertom;675283]I like the way your bike looks---you did a good job---plate holder looks good (you guys sure have a big ass plate)---so simple to make
and cheap too---you didn't ask but---I would cut about an inch off that break lever so it is shorter than the grip and finish it off so it looks
like it came that way---also if you got some clear reinforced fuel line for your brake reservoir you could shorten the length that you have
and be able to see the amount of fluid that you have in it so you could adjust the amount as your brake pads wear---just my .02 cents.[/QUOTE

Thanks. Will try and get all those niggles sorted out over the next couple of weeks. :cheersmate: