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I wanted to keep the rear wheel stationary and the way my fender covered the tire would not allow the axle to move. I did not want to move the axle back to tighten the chain, so I went with a chain tensioner. Had to cut a plate to fit the corner of the hardtail. Then I lined it up to the chain and welded it in.
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Now to mount the oil tank. Grabbed some rubber isolators from Speed Dealer and made some brackets out of flat stock. I'll be dressing it all up with SS button head bolts.
I had an issue with the position of the oil feed. The chain was right in the path. Simple fix, welded it up and moved it to the left side of the bag. It would be better on the left side since it leans that way on the kick stand.
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Time for a battery box. I was going to buy one, but I didn't want to wait for shipping. So, I built my own box. Started with a cardboard design, traced it out to some metal flat sheets and used my plasma cutter to trim it out. Cut out some more brackets from flat stock to use for rubber isolators. Then jigged it all up and tig it together.
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Fender mounts and fender strut mounts installed. Fender struts was some round bar bent and welded to a couple nipple bungs and counter bore bungs. I tapped the hole on the Led Sled hardtail to attach the strut.
Seat mounted and ready to test.
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I didn't want to lose my tank size and I liked the look of the stock tank. I didn't like the stock mount angle for what I was building. I wanted it more inline with the backbone and didn't want to use a lift kit. Plus, I liked the empty void look between the front cylinder and the frame. I decided to weld in a new tunnel instead of purchase a new tank.
Out with the old tunnel and in with the new.
Picked up some flat stock, broke out the torch and got to folding and cutting. What a bitch! But, I think it turned out okay and the way I was seeing it.
Rough looking on the welds, but I used a KBS Coating kit and sealed it up. No leaks. I'll take some kitty hair to the outside and smooth out the seams before I paint it.Comment
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Since I cut out the stock fuel valve and changed the angle of the tank, I wanted to get all the gas I could from this tank. I installed a fuel bung on the rear, lower end for a Pingel valve. I completely removed the vacuum system from the bike.
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good work with the tankComment
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Cut out some metal to position my rear brake similar to the original setup.
Welded up the tank mount hole and smoothed it out.
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Time for some exhaust. Since I could not use my stock exhaust due to the 180 hardtail, I decided to get a builder kit and weld up my own. I made it nice and tight and followed the lines of the hardtail. Here is the front exhaust mocked up.
Rear exhaust next.Comment
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I zip-tied the back-half of the exhaust to match the line of the other and worked backwards.
I really was dreading making these, but just cut, mock and tack all the way through. It took a couple days to get it correct along with some tool throwing. Turned out exactly how I was picturing it. I couldnt be happier. Spend the next couple hours fully tig welding them up.
Last edited by KeyserSoze01; 09-07-2015, 5:36 PM.Comment
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Few more pictures of the exhaust being smoothed out. Just used an air grinder and light grit.
I'll have a chromer finish them out and get them chromed.Last edited by KeyserSoze01; 09-07-2015, 5:52 PM.Comment
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Looking really good man nice work!
I have the +2 hard tail, found it locally for cheap, but kind of wish I went with the +4 cause right no I have NO room for a tensioner. I kind of did a similar set up on my tank but just made new mounts rather than making a new tunnel - I like the way you did it - more work but looks better. Right on.
Stoked to see the rest come togehterComment
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Wiring ? im working on a 99 rigid sportster. just curious what you have in mind.Comment
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Alright, let's continue this project. Since I removed the ignition module over the front rocker, I needed to fab something. Grabbed some flat sheet and just started bending.
Placed the ignition module on it and notice it needed some better support.
Welds look like shit, but nothing a little paste can't smooth out. PC'd and turned out great.
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