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  1. #1

    Default First Build...2001 XL1200 Sportster on a Paughco hardtail

    Hey guys..I'm brand new to the site..So I've been riding now for years and always wanted to build one of these. I'm finally getting my chance albeit feeling a little overwhelmed.. Finally got all the pieces/parts in. I'm fairly handy and know basic mechanics..Thats about it..I'm sure this will be a real learning experience.. Now, what do I do with all this stuff again?...

    Here's my donor bike and start of my mock up..I should be able to post about weekly.. Ideas, hints, clues, suggestions..are all welcome.. Thanks.
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    Last edited by Pcruz1201; 01-15-2017 at 6:29 PM.

  2. #2

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    Now that I look at the photo closely, I may opt to go with a smaller tank.. any suggestions?

  3. #3
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    Those Paughco frames look good.Is it EFI or carb?In my opinion,those late model sporty tanks are among the worst looking tanks around.It's your bike do what you want,but if it were mine I'd be installing a different tank.You can probably get an EFI tank with more traditional shape from Lowbrow,Throttle Addiction or Bison Motorsports.

  4. #4
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    Guess it's carbed as it's not a rubbermount, but if it wasn't I'd switch it to carb. Efi sucks.
    Anyway, that giant ass tank is hideous imo too, had it on mine and I replaced it with a classic small sporty tank. You could get a wassel or axed too, that's all personal preference. Actually a medium tunnel wassel would look nice on there

  5. #5

    Default

    yep its a carb.. Yeah the more I look at it the more I realize tank needs to go. Also may have a clearance issue once I install my drag bars.. currently have a three inch rise on that springer and with that tank it just won't make it.. Its ugly..I agree.. thanks for the info!

  6. #6

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    Also changing out rear wheel.. and chopping rear fender a bit.. Going with a 40 spoke rear.... working on her today.. should have more pics in a couple days..

  7. #7

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    More mock up pics. Took some good advice and went with a smaller thank.. This one is from Throttle Addiction. Good quality tank and nice welds. I think the bike is looking a lot more aggressive with this tank. I'm starting to like it..Click image for larger version. 

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  8. #8
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    Default

    Nice! Fork is +2"?

  9. #9

    Default

    Thanks. Its actually standard 30" but it does look longer. Maybe its the 21" tire.. Def like the stance though..

  10. #10

    Default Bend Struts...check

    Working on my fender struts today. I need a "Man Sized" Vise.. But I guess I figured it out. sort of.. may need a little more work.. One small vise and two clamps for moral support..haha! using these bungs as well to mount..
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    Last edited by Pcruz1201; 01-12-2017 at 4:17 PM.

  11. #11

    Default Chop Fender..Check.

    Fender chop.. I think I like it..
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  12. #12

    Default Meanwhile.....

    Taking this Sporty apart slow and steady.. Had a few headaches already but trying to take things off the bike as an assembly to make it easier to reassemble on hardtail later... Almost ready to transplant the motor..
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    Last edited by Pcruz1201; 01-13-2017 at 9:11 PM.

  13. #13

    Default Making Progress

    Finally almost ready for a real mock up... It was a pain getting it out of the frame but I got it. A little "persuasion" and BINGO...its out..


    Kind of a lot caked on dirt/grime/oil on it. Any ideas on a good cleaning product for this? Thanks!
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    Last edited by Pcruz1201; 01-17-2017 at 12:07 PM.

  14. #14
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    Kool Build. Watching as I've had and loved 2-'76/'80 but not knowledge of the new ones. My '80 the easiest way to get the motor back in the frame is either, lay frame on it's side and lower the motor into the frame OR motor on side and drop frame over motor. It's been yrs since I had mine but I did fight it to get it out of the frame at first. Hope this tidbit helps but I did it before putting the frame together. Keeping it Simple for my old mind..lol Continue on!
    I rode my '80 to Sturgis from South Louisiana in "92, 14 days, what a trip!

  15. #15

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    very cool thank you!.. I got it out, it basically fell out of one side as I wiggled it out.... now to get it in the new frame for my final mock up..

  16. #16

    Join Date
    Dec 2016
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    Default

    Quote Originally Posted by Pcruz1201 View Post
    Kind of a lot caked on dirt/grime/oil on it. Any ideas on a good cleaning product for this? Thanks!
    Simple green works well, its safe for chrome, paint etc. so you can just coat everything and let er soak

  17. #17

    Default

    cool thanks! I'll try it..

  18. #18
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    Default

    Castrol super clean is by far my favorite degreaser, s100 also works just as good if not better but is a bit more expensive

  19. #19

    Default More mock up and frame prep

    Just some pics of my progress...chopped that fender support that Paughco gives you..Also had to grind down the center a bit to weld on oil tank tabs and seat bungs..

    It was tricky getting that motor square in this frame.. A little crowded but its going to look nice! Overall pretty happy on how its turning out..

    Let me know what you guys think so far...
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    Last edited by Pcruz1201; 01-24-2017 at 6:45 PM.

  20. #20

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    forgot to add one more photo of the other side..Click image for larger version. 

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