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  1. #1
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    Default First ground up hardtail build 2002 sportster

    The beginning of this year I started building my sportster from nothing. No donor bike or motor or frame. I had plans of buying a bike as a donor and doing a weld on hardtail but the guy I bought it from fucked me over and the bike never got shipped. Lesson learned NEVER send money as friends and family thru PayPal. Trying not to be discouraged I pushed on and bought a paughco frame off eBay as a starting point.
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  2. #2
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ID:	98200As the frame was being shipped I stopped at my local Indy shop and seen if he had anything I might be able to use. I scored a 39mm front end and a 16 inch rear rim. Ordered some tires and a 21 spool from TCBros along with a sporty tank. Had an old piece of fender laying around that I threw up on the wheel for good measure.
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    Last edited by smurph123586; 4 Weeks Ago at 4:05 PM.

  3. #3
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    Looks like a great start, man. I look forward to watching this come together. What are the specs on your frame?

  4. #4
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    After getting the frame to roller status. It was time to start looking for a motor. Came across a deal about 3.5 hrs from me. Nothing special 2002 883cc with about 12xxx miles from a salvage bike. Came with a carb and coil. Engine physically looked really nice. Compression numbers were in specs so home it came with meClick image for larger version. 

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ID:	98202 ended up ordering a air cleaner and shotgun pipes as well

  5. #5
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    30 neck (stock) zero drop. Zero stretch

  6. #6
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    Cool, thank you. I've been eyeing their Swedish Sportster frames for a long time, but the custom build registration process is too big a hassle up here. Paugcho seems to have a good frame building reputation.

  7. #7
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    So with the motor in. I picked up and oil bag, rear fender, and mounts. I had made some temporary wheel spacers out of PVC as I don’t have a lathe to turn my own spacers. So I had my buddy “flying tit” come over and measure them out and cut them for me. While waiting on those I cleaned up some of the frame tabs and mounts that I wouldn’t be using. And started to look at tank mounts as well. Click image for larger version. 

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  8. #8
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    Quote Originally Posted by AlbertaFarmer View Post
    Cool, thank you. I've been eyeing their Swedish Sportster frames for a long time, but the custom build registration process is too big a hassle up here. Paugcho seems to have a good frame building reputation.
    I’m from Iowa. I was very nervous about it at first but the inspector was super cool and made it very easy for me. But yeah for the money I think they are great frames. I hear some people talk trash about the welds (mig) but honestly they aren’t bad.

  9. #9
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    Sorry for the photos... can’t seem to figure out how to rotate them? Anyway.. as “the flying tit” is getting ready to machine my spacers I decide on a brake setup. I search and search for something cool yet functional. I see fab Kevin’s dual caliper setup and hangers. But after talking to a few guys out of Rockford (drit and mike of the Tramps) that put some serious miles on their bikes. They tell me they use the stock rear Harley calipers. After picking one up I come across a problem. The mounting area is to wide to fit between the frame and line up properly with the rotor without binding. So off to the local machine shop to have it milled down. Click image for larger version. 

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  10. #10
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  11. #11
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    So as I keep trucking along with the build one thing that I over looked when ordering the frame was the placement of the battery. After the fender was aligned and mounts were welded in place I thought “fuck where is this battery gonna go!!!?” Or is there a small enough one to fit in this spot?Click image for larger version. 

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    Fortunately after some measuring I found that an antigravity battery would fit in there. I ended up cutting out the paughco rear fender mount. That big ugly triangle piece and just welding in a plate to mount the battery and my lower fender mount. Click image for larger version. 

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  12. #12
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    So at this point I threw a set of bars on it just to move it around the garage.

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    The day finally came where I could put it on the ground and see what she looked like. took me about 3 months to get to this point and a decent credit card bill. Chopper build on credit.

  13. #13
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    I started this project January 3rd when the frame arrived. So now it’s mid March in Iowa still cold but able to move this bike to the tits house were we build our first sissybar. He had a legit weld table so I figure it would be way easier to take measurements and fit everything there. Click image for larger version. 

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    The bottom mounts he decided to make these beautiful tapered pieces to slide onto the ends and bolt into the sissybar.
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  14. #14
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    So back in my garage I have a go at making a seat. Ducting tape and tin foil as a base to make the fiberglass pan. A $10 yoga mat I trim up for foam. Long story short I could never get it comfortable on the tailbone so I ditched it for a spring seat. I know. I know. I’m not happy about it either but it was starting to get nice in Iowa and I was itching to ride. Click image for larger version. 

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  15. #15
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    Shake down run to the local bar.
    Last edited by smurph123586; 4 Weeks Ago at 8:05 PM.

  16. #16
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    I won’t bore you with the whole tear down for paint and powder. Basically I moved the rear tail light and and added the license plate to the sissybar. But this is as it sits. I DO have spark plugs in it now and have ridden very little

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    Since those pics I’ve put a few miles on it before putting it away for winter.

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