2000 Sportster Treatment

[SoulCal1]

Oh yeah, pipe came out killer! Rear fender looks sweet as is. Curious to see what plans you have for a seat.

[Boylecomm]

Today Matt "TheOldPro" finished trimming down the stock wiring harness & wired up all lights, switches and she fired right up.
I'm stoked on the the sound of that pipe.
Now clean it up the make a couple of switch brackets/boxes and check, off the list.

Thanks Matt!

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[Vassago]

Question on the cam cover chop, did you have to pull the rocker box covers and top off to relieve tension on cams in order to pull the cover to chop? It looks like in your pic that you left the engine top all together and just pulled the cam cover off.

[carl609]

Sweet looking bike man. Cant wait to see the finished product.

[Boylecomm]

You may need a gasket and I cut the ignition wires and spliced them back after. Other than that it unbolts and comes right off.

Question on the cam cover chop, did you have to pull the rocker box covers and top off to relieve tension on cams in order to pull the cover to chop? It looks like in your pic that you left the engine top all together and just pulled the cam cover off.

[mike1407]

You may need a gasket and I cut the ignition wires and spliced them back after. Other than that it unbolts and comes right off.

i thought you had to bleed the lifters, to keep from damaging the brass bushings

[Boylecomm]

Entirely possible that it's recommended.
I blindly just went for it, the cover slid off and on very easily & I'm very confident there was zero bushing damage. I ran it yesterday no problems, no leaks.


Anyone know the proper procedure?

i thought you had to bleed the lifters, to keep from damaging the brass bushings

[theOldePro]

I chopped my cam cover and did the same as Boylecomm......kept the top end in tact, didn't loosen anything other than the cam covers bolts. going back on, I had to tap it with a mallet a few times, but nothing out of the ordinary.

please do tell if there is a proper way to do this.

[mike1407]

i guess the proper way is to remove the rocker boxes to relieve pressusre off the lifters, i was just informed that letting the bike sit, also did the same. idk im no expert, ive seen some other do it the same way w/ no problems.

[ruckus2115]

I chopped my cam cover and did the same as Boylecomm......kept the top end in tact, didn't loosen anything other than the cam covers bolts. going back on, I had to tap it with a mallet a few times, but nothing out of the ordinary.

please do tell if there is a proper way to do this.

i took my rocker boxes off to relieve the pressure on the cams. so yea i did have to buy new gaskets and everything but it was all pretty easy....i have posted this picture in another thread but it shows what i took off....

[Vassago]

i guess the proper way is to remove the rocker boxes to relieve pressusre off the lifters, i was just informed that letting the bike sit, also did the same. idk im no expert, ive seen some other do it the same way w/ no problems.

Yup that’s what I heard, but it sounds like allot of people are doing it without the top end being removed. My luck it will be my ass that should have removed top end while cams are flying everywhere.

[Boylecomm]

We had some good company around all weekend so I didn't get much accomplished.
I did do this little tank detail.

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[Boylecomm]

I finally got started on the rear fender.
I decided to use the upper shock mounts and the existing center tab as the mounts.
I should've thought ahead & ordered a fender with a 2" skirt from Front Street Cycle but I didn't so I welded on some fender skirts.
Recycled some 1/2x13 bungs from a set of long dead Biltwell bars.
Wedged the fender between the bungs drew a rough shape and cut it out. Then tacked & finish welded the bungs. Pulled the bolts and somewhat cleaned up the fender shape and drilled the threads out of the bungs as counter sunk 12/x 13 socket bolts will come in from the inside of the fender and the shock bolts from the opposite side.
I still have to dial in & weld the third mounting point and the fender shape will change a bit, maybe be cut shorter as well.


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[Jackieshan]

Looks great! I'm really liking that fender cut. You've got a really cool style. I'm really thinking you guys at benchmark should start mass producing some of these things you incorporate into your bikes. I don't know, but maybe something like that fender? Or some pipes perhaps? Or even the little cable guides. On second thought, maybe not such a good idea... I'd be spending way too much money that I don't have. Keep up the good work!

[BehindBarsInc]

Thing is lookin good! It's a pretty inspiring build... Can't wait to see it done

[JohnnyWolf]

Nice, I mounted my rear fender the same way.

[Boylecomm]

Thanks All.
I'm real pleased on how strong the fender mount is.
I'm looking forward to riding this thing.
Seat pan tomorrow.

[SoulCal1]

The fender came out sweet! I like the way you mounted the fender -- nice and simple! What width fender did you use?

Finding the right seat for a sporty is tough. Curious to see what you are going to do. Thanks for the pics!

[OldGoldGarageCo]

Looking great Kim.

[Boylecomm]

Thanks all.
I'm enjoying tinkering with this bike & I think it'll be a fun rider.


Well I had a half assed goal to have the tank & fender ready to go to a painter by the end of this week but I forgot I'm going out of town.
I still wanted to post some sort of progress so between a couple small Bench*Mark fires that had to be put out this week this is where I ended up. 48 or 72 pin holes filled & tank sealed/red coat, Fender mounts done, hammered out & mounted an aluminum seat pan (the shape is Not quite finished) & we were thinking the fender was looking a little plain so I started on this stainless fender trim.
I'll finish up these couple of bits when I get back middle of next week or so.




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