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  1. #1

    Default 1999 sportster 1200 "FIRST FRAME UP BUILD"

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    Hello everyone,
    Dantheman here first off I'm new to this whole forum thing, good or bad any criticism is better then none btw..
    So I got this 1999 xlh 1200 sportster about 4years ago picked it up for 2k with 22k miles on running a bit ruff at the time how you see it here is the day I got it..previous owner picked it up and could'nt get the bike to run rite...after looking at it and wanting to do a custom build thought it would be a good platform to start with... after tinkering around with it when I got home it ran pretty good so I ran the bike harddd for 2 seasons until it was starting to get a bit tired so at that point it got thrown in the back of the garage until I could find time and some spare cash to make it different as this being my first really gound up build time gets the best of projects like this and after a year or so collecting dust and not have time to really get balls deep in it got put on the back burner as I had 2 other bike at the time...so now july 2019.. i started full tear down to bare frame and to start this long awaited project...the problem was everyone builds sportsters how can I make mine different and stand out...I'm 28 years ive bin riding for 10years and have many bikes that turn into projects and changing parts but I wanted this one to be different I'm a heavy equipment diesel tech. And motor builder so I have experience with welding and fabrication exc. This is how it started

  2. #2

    Default Breaking bike down to start build

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    NOW fully apart I decided to clean the frame and swing arm remove all bearings and races, clean up the frame and sprayed it in my garage black again with 2 coats and a clear...while it dried I tried coming up with a plan on what direction I wanted to go with this and absolutely I have a budget with that being said my budget for the bike is 3k all said and done..with me doing absolutely as much work and fabrication as I could in my garage at home...I wanted it to be sleek,fast,light, controllable and try to make it stop great with it being a brick and outdated while trying to stay in budget was the issue

  3. #3

    Default Design and configuration

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    I started by drawing up a sketch of what I liked and what i wanted it to look like or get it as close as possible lol...then i took measurements of everything from a custom swingarm to custom suspension making new shock mounts..to modifying triple trees custom oil tank and modifing tank and tins axles and breaks..rider weight and sag while making sure it was possible by using all stock stuff that was on the bike to start with so idont blow the budget and how to make this possible!!! I SCRATCHED MY HEAD FOR A WEEK STRAIGHT...waking up at night to just rite something down and trying to figure out how that could be possible finally I made finished up these blue prints on paper that could get me close enough and learn on the go also so then the motor I called my buddy alex at hammer performance and went back an forth on how to build a 120hp evo sporty while staying in my budget he laughed at me and said well I like you style let's try it so I did some bartering and got a set of screaming eagle bin fin heads and had them stage 3 port and polish them got a 1250 big fin jugs and pistons 600 sledge cam Jim's hydro big travel lifters and buell push rods roller rockers and 7mm stems titanium retains and beehive springs while they did all the machine work I dissembled the motor clean prepped clearanced the case and lifter gallies..up dated the tranny and did absolutely everything to get ready for the parts to come back from them there where alot of all nighters but the parts came back and couldn't be more happy with the work they did then I assembled the motor Click image for larger version. 

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  4. #4

  5. #5

    Default Motor assembly

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  6. #6

    Default Theres a fucking budget!!!!

    So yeah I spent 2100$ on the motor parts gaskets clutch machine work oil pump exc... trans up date parts and everything for the motor to go in wow well that budget almost went quick...now was the time to really same and save as much stock parts and modify them...and it was a couple weeks of constant cutting fitting drilling and milling bunch more all nighters so many I actually put a coffee maker and a beer fridge in the garage lol and now parts are coming together finally Click image for larger version. 

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  7. #7
    Senior Member

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    Default

    Very cool, man. Looking forward to seeing how this one ends up.

  8. #8

    Default

    Alberta farmer... hey man thanks well I'm actually almost completely done with build just got a bit busy to finish the rest of the posts it's almost ready to be dyno tuned I'll post what I have shorty

  9. #9

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ID:	96891 so honestly I have everything 600 pictures from start till now ...july 2019 - September 2019... and this is a spoiler but gotta throw up a picture of it now...SHORT summery I made a 5inch extended swingarm out of a stock one 4040 tool steel welded with 2inchs of it in side both sides of the swing arm the centering and leveling jig took a bit to make and reinforced it...drilled tapped and custom made bracket for headlight relocation on lower thriple upper trees I taped all the way thru for a custom digital display tuner and dash fro. Europe that I made bolts brackets and rewired and pinned harness for made aluminum solid mount riser bushings and took a set of 2007 yz450 dirtbike risers and machined new mounting bolts and risers for 1in fly internal wired bars then stripped tins and polished them cut and welded gas tank ...to be lower...530 chain drive kit....48..23 tooth....modified original back fender cut striped and polished raw made front motor mounts and top coil relocation motor mount polished fork tubes making a internal part of subframe horseshoe type oil tank for a sleek look and integrated lithium battery tray new tubes and tires polished rims hubs and spokes custom made a brand new wiring harness with all Deutsch connectors double weather proof seals...mechanical oil pressure gauge shuck mount relocation and adjustability making aluminum fork brace...also made floating rotor rim spacers and dirtbike reversed lower chain guide and so SO MUCH so much more I'm actually whooped the fuck out this build is so ambitious for the time frame sorry for rushing everything but I'm still pulling all nighters and I'm so close to finishing it then tearing it down to clear and powder coat everything theres so much I'm missing but that's just a little bit of the work I did so far and so much to write up and I'm short on time at it is guys hope this is helpful for now lmk any...issues or concerns with anything I'll try to post the whole build when I can but for now I'm missing everything in between but this is what it looks like now thanks for understanding

  10. #10

    Default Almost 2 months of work

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  11. #11
    Senior Member

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    Looks good!

    Detailed pics of fabrication also welcome.

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