CHOP CULT HOME
Email Password
Search
Page 1 of 4 123 ... Last
  1. #1
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default '78 XLCH learning how to build, build.

    Ok, so a little bit about me. I have zero mechanical experience except fixing my car with my dad, and working on my bmx bike. I still canít figure out my mountain bikes. I started with an í81 Honda cb650c, fixed it a little bit and rode it for a year or two. Then got a í75 cb750k, which needed a lot of love so I was able to get my hands a little dirtier. Then I wanted to get into the chopper world, and picked up this í78 XLCH sportster from a guy who owned it for the last 25 years. This is what it looked like when I brought it home-



    Got it in fall, rode it around a bunch and throughout the winter since I was pretty close to work at the time. took the apes off cause I really wasnít a fan. Girlfriend was a champ about it-



    My opinion about bikes changes all the time as I get more into it. So the apes went back on. I think these forks are about 4 over, which I also wasnít super into



    So I put on stock length (maybe?) and some fork gaiters.



    then put some biltwell chumps on there, since I liked the look of the apes but not the big rise. then rode it around like that for awhile. took it to some riding spots



    another view of the chumps


  2. #2
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    wanted to start cleaning it up a bit, so I bought a grinder and started removing the reflector perches and fender mounts



    after grinding I used some hand files and eventually some kind of sandpaper. could of been more anal about it but looked good enough for me



    then I started thinking about hard tailing.. started collecting some parts and mocking it up. at the time I was stoked on how it looked



    wanted to stop those pesky oil leaks, so googled how to take off the pushrods. and replaced the cork seals








  3. #3
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    in may I finally had enough cash to order the hard tail. went with the david bird because I really liked how it looked as a bolt on, and I had never touched a welder before. 5-6 week turn around time, so it arrived 3rd week in June. Strange Days was a few weeks later. time to start hustling.



    new stuff



    old stuff



    well, time to start chopping






  4. #4
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    went on without too much persuasion, and I started laying parts on it again



    rolling around



    got a seat which I canít remember the brand, some 3Ē springs, biltwell tongue thing and some spring mounts



    started trading bottles of jack to my buddy to borrow his mig for a week at a time. this is literally one of the first welds Iíve ever done, in hind site I probably should of practiced for an hour or so, but I was too excited and just went for it. oh well



    starting making a fender support to weld to the frame














  5. #5
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    had to cut away part of the hard tail to fit the tongue for the seat far enough back





    more weld attempts



    bent some metal to weld onto the frame for the first support, tried to match the contour of the trailer fender I got from lowbrow





    fender mounted to frame at the chain stay and seat stay (hopefully those bike terms transfer) and spring posts and seat thing welded on



    had to buy a tap for the sissy bar support


  6. #6
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    friend had a tank laying around, thought it looked much better





    license plate bracket time



    complete with walmart trailer light



    instagram shot of welding





    attaching the thing that the license plate bracket will attach to

    Last edited by jaycagney; 04-27-2014 at 12:29 AM.

  7. #7
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    my bike is turning into a storyboard of my welding technique progress







    exhaust pipe was hitting the new frame, so I dented in that section by squishing it around some 1/2Ē round rod. I think I just ended up using a hammer, it was easier



    clears just enough, more than it looks from this angle




  8. #8
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    made a sissy bar by putting 1/2Ē mild steel in the vice and just pulling on it real hard. donít have the heat capabilities. used the lowbrow kit





    almost there



    then I had to move. that didnít help the building process. borrowed the welder again and my girlfriend played with it



    had to make exhaust support, so welded on this piece and cut it off above the lowest hole



    now weíre supported, front and back



    itís together, and the test ride felt awesome. this was thursday night. Strange Days started the next day, Friday. phew.


  9. #9
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    rode it to work Friday morning, and it made it there and back. good enough, time to pack up for Strange Days







    it was a blast to ride, and was tuned super well. started up first kick all weekend, and I was all smiles that it didnít explode. kept riding it all summer, didnít come without issues



    let the girlfriend take it for a ride, sheís only ridden my hondas before this. she got kinda hooked




  10. #10
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    relocated my coil. in a very ghetto way



    attempted my first set of handlebars. pretty much just took the specs from the biltwell H bars, figured no bends was in my ability





    the next big thing was Gypsy Run. never done a trip that long, but this was the week before. scrambling to get everything sorted again. chopped the springs and lowered my forks another 2-3 inches



    got it together. replaced my bald back tire, which is bigger, so had to make a new sissy bar. also made that bigger.



    packed and ready for gypsy run. my girlfriend is joining on my cb750



    it was super fucking awesome. great time.

    Last edited by jaycagney; 04-27-2014 at 12:32 AM.

  11. #11
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    until I broke down. I was at the back of the pack we were with and no one saw me drop out. luckily they didnít get too far and came back. the guys from lowside tried to help me out, but my bike was toast. it was having problems all day, so I got a lift to the final camp ground. my girlfriend continued on with them, without me, with less than a year under her belt. gnarly.



    so what happened is on day 1, my points went. luckily I had an extra set with me, but while I was changing them out I knocked the positive wire off my battery. I have no electrical experience so I pretty much had the worst electrical harness ever, and just mashed everything into a plastic box with electrical tape. my generator must of somehow became unpolarized, and my bike stopped charging. and it was way out of timing because the new points, and me not knowing how to set timing on the road without the internet. a guy Nick was nice enough to loan me his extra battery so I could try and ride home the final day, and it didnít fit into my tray. so we got a little creative with zip ties. you can also see how bad my wiring was



    it got me an hour towards home before it ran out, and luckily my buddy was hanging with his truck at the final night so we threw it in there



    however, my girlfriend successfully rode the whole way home



    the next week I got my generator rebuilt, got a new regulator, and was back on the road for brooklyn invitational. my bike was fine, but the cb750 fouled a plug and while we tried to get it out with needle nose vice grips due to lack of tools, we shattered the ceramic. the bike stayed in brooklyn and we went home at got the truck. the bike then sat until this spring when I finally got around to it, since my girlfriend picked up her own í96 sportster.



    new biltwell seat, so much more comfortable than the other one


  12. #12
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    had some sweet fall rides, with little to no issues except the bolt that holds the advance mechanism broke off in there, but that was an easy fix, just took me out of commission for the next few days. I proceeded to show up to the secret bike show on the back of my girlfriends sportster. everyone thought I was rad.



    this is how she ended the year



    so now it’s cold.. and I’m thinking longer forks. found a good deal on some 6 over tubes



    girlfriend got me the sweet throttle addiction tank. I picked up a new solo seat



    got my hands on my own tig welder. way harder than mig. I suck at it.



    mockups of my new stuff and my old parts on my girlfriends new bike



    well better than my first tig attempts



    cleaned the garage, and got to work. started by chopping off the posts on the spring mounts, but left the fatter area of the bungs for the seat to sit on since the frame isn’t a straight line

    Last edited by jaycagney; 04-27-2014 at 12:36 AM.

  13. #13
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    engine came out, time to work on the frame



    new seat



    I dig the forks







    wanted to try and make the david bird section look more naturalÖ








  14. #14
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    what I donít have photos of, I put a 1Ē bar across the seat spring perches to support the seat, and used a bit of bondo to kind of mold some of the areas around the seat to make it look more flowy. on to paint



    nothing fancy, just flat black grill paint. maybe Iíll do it right someday, but not today



    cleaning, and grill paint on the jugs



    first time using scotch brite. canít believe how well it works



    starting to reassemble



    made bungs to weld into the frame to mount the new tank in a more solid manner








  15. #15
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    fixed the honda, and rode it to work while this thing was in pieces



    progress, all painted up



    new coil that didnít have cracks on it, mounted it properly and new plug wires. maybe should of taken care of that lower gasket while the engine was out. oops.



    relocated key right under the right side of my seat so I can turn it off with my hand on the clutch



    drew wiring diagram based off of numerous threads on here



    old army box thing, and some bed liner for the battery box



    the dividers separate the circuit breakers. probably could of done it better but, you canít see it.


  16. #16
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2013
    Posts
    150

    Default

    also not pictured- removed the oil cooler mounts and oil cooler. relocated oil filter to above the battery box. itís kind of in the way for taking off the lid now. will do something eventually. managed to clean up the wiring a good bit and have 2 wires to coil and 1 to headlight. took it for a test ride, felt awesome, but made a horrible noise. not stoked. turned out a pushrod seated or whatever and I readjusted them and the noise went away. phew. welded kickstand to itself because the spindle was stripped. doesnít spin anymore.





    got rid of the swing out kicker arm, and put a brass pedal on. pedal fell off in the first 5 minutes, so I got a new brash washer, bolt, and lots of locktite. seems ok now. also chopped the end of the pipes off and put small baffles back in. bikes much happier now.



    got some stainless, and my girlfriend and I made new handlebars. on easter.



    more pulled back since my seating position is farther back now



    also, that matte black paint isnít that matte black paint everyone has. its chalk board paint. I can make my bike look ridiculous whenever I want now, and when Iím over it hose it off. been riding around with electric blue for a week



    I will probably be a bit more subtle with the chalk in the future. but Iím excited about the possibilities. Iíve learned a whole lot so far with the project, and I've used this website as a resource for most of it. itís far from perfect, but at least I know I touched every part of it.

    the things I have left to do are- machine front axle to accept drum brake wheel that I have. mount new tail light. buy new headlight, preferably a rectangular one and mount that. and make new/buy new foot pegs. maybe also get a smaller air cleaner, and a different oil tank. but Iím super happy with where itís going for sure. Iíll try and update as it goes forwards.

  17. #17
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Feb 2011
    Posts
    576

    Default

    Good job man and way to jump on it and learn.

  18. #18
    Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Mar 2014
    Posts
    79

    Default

    Awesome. Makes me feel like I have some hope for mine next winter

  19. #19
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Sep 2012
    Posts
    282

    Default

    Awesome thread. Thanks for taking the time to post this. Very cool.

    The chalkboard paint tripped me out at the end. Interesting idea.

  20. #20
    Senior Member

    Content on this page requires a newer version of Adobe Flash Player.

    Get Adobe Flash player


    Join Date
    Oct 2011
    Posts
    1,897

    Default

    Cool bike and nice write up. Thanks for taking us on the journey.

Share This



Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Log in

Log in