Sportster Cafe Build - Burly Brand

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  • BurlyBrand
    Senior Member
    • Jul 2011
    • 368

    Sportster Cafe Build - Burly Brand

    Stepping outside our comfort zone again. Scrambler build went pretty well and for those of you that gave us props, it's much appreciated. This time we're looking to transform a raggedy Sportster into a legit Cafe. If all goes well, we'll create some new parts and maybe learn something along the way. As always, your input is appreciated.

    Our victim this time is a pretty sad 2003 883. It was a test bed for our cable kit program and then stuck in a corner to rot. Clogged carb and very dead battery attest to that.

     photo IMG_0485_zps27e5cc45.jpg

     photo IMG_0495_zps379745c4.jpg


     photo IMG_0511_zps2b48f72a.jpg
    Yeh, somewhere along the way the airfilter went missing.


     photo IMG_0507_zps661b4584.jpg
    and one of the risers shattered. A really really long time ago.


    For now, we'll use the stock wheels and maybe some vintage looking Avons. Probably start by stripping off all the unnecessary parts and weld up a set of Clubman bars. That should give us a feel for what it'll take to make an ass-low XL into something that wants a level looking chassis.

    More pics on the way as we break stuff. Stay tuned for another action packed episode of "Sportster and Sawzalls" some time next week.
  • CoyoteUSP
    Senior Member
    • Mar 2011
    • 520

    #2
    Yessssssssssssssssssssssss

    Comment

    • Nosebleed
      Senior Member
      • Mar 2010
      • 2410

      #3
      (Nose goes to make popcorn)

      You guys want some?

      Comment

      • Jackfrost
        Senior Member
        • Aug 2012
        • 210

        #4
        Oh goody here they go again

        Comment

        • Saltytonk
          Senior Member
          • Mar 2011
          • 2585

          #5
          Yep I'll be watching this one too!

          Comment

          • RAT
            Member
            • Sep 2011
            • 41

            #6
            Sweet, that scrambler is titty balls! Looking forward to this...

            Comment

            • RAT
              Member
              • Sep 2011
              • 41

              #7
              also, you gotta keep the clutch cable like that

              Comment

              • hutchings
                Senior Member
                • Sep 2010
                • 481

                #8
                Subscribed as always!


                I won't spoil this one for everybody.. but I bet after seeing the pipes going on this thing, the direction it's headed is gonna be great!




                Cough*DPCustom*Cough

                Comment

                • nunez8853
                  • Apr 2024

                  #9
                  this is exactly what i wanna see. a cafe sportster, i wanna do one of those so bad. once i have the coin i will for sure

                  Comment

                  • BurlyBrand
                    Senior Member
                    • Jul 2011
                    • 368

                    #10
                    Stalker!

                    Yeh, we scored a super rare DP Customs box pipe. Pics soon enough.




                    Originally posted by hutchings
                    Subscribed as always!


                    I won't spoil this one for everybody.. but I bet after seeing the pipes going on this thing, the direction it's headed is gonna be great!




                    Cough*DPCustom*Cough

                    Comment

                    • BurlyBrand
                      Senior Member
                      • Jul 2011
                      • 368

                      #11
                      Bike strippage is in play.

                       photo IMG_0563_zps06d8ccb0.jpg


                      We really like the look and convenience of Clubman bars (no drama relocating speedo or dealing with a top triple clamp), so we've mocked up a set. Pulling wires internally is a pain, so look for an update that makes that much easier.

                       photo IMG_0568_zpsd5e18641.jpg


                      Cafe styling will want a much taller rear-end and likely lower fork to achieve a proper level chassis. Tentative plan is a set of the new 15" Stiletto shocks in the back and a 2" drop in the forks. Both will firm up the suspension which will also pay off in handling characteristics. This thing needs to do more than just impress hipsters, it'll need to rail corners as well!

                      Comment

                      • NHMike
                        • Apr 2024

                        #12
                        Looking forward to seeing how this tunrs out. Saw a pic of a bike with the Stilletos on it and they looked badass.

                        Comment

                        • BurlyBrand
                          Senior Member
                          • Jul 2011
                          • 368

                          #13
                          Tall shocks are the secret sauce to transforming the XL chassis into a proper Cafe.




                          Originally posted by NHMike
                          Looking forward to seeing how this tunrs out. Saw a pic of a bike with the Stilletos on it and they looked badass.

                          Comment

                          • derekd403
                            Senior Member
                            • Jan 2012
                            • 791

                            #14
                            Originally posted by RAT
                            Sweet, that scrambler is titty balls! Looking forward to this...
                            I wanna subscribe in hoping this turns out "titty balls"

                            Comment

                            • BurlyBrand
                              Senior Member
                              • Jul 2011
                              • 368

                              #15
                              We're not even sure what that means....


                              Originally posted by derekd403
                              I wanna subscribe in hoping this turns out "titty balls"

                              Comment

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