SBS Project - Sportster Chop w/ Lots of Photo's

[FuzzyWuzHe]

Dang Kevin ... that is why you don'y need me there ... I would of never thought of a threaded bung ... although, I'm pretty good at sitting in the folding rocking camp chair with a glass of Iced Tea or Soda ... ya know, Stupervising.

I have to admit, you guys are doing it right. Don't let the ants in your ants get you in trouble ... been there, done that.

[DK Custom Products]

Next up was to drill the full size hole for the bung...



Threaded bung sitting in hole we just made.



Perfect! Next time the welder is over we'll get that bung welded in, along with a spring stop for the tensioner, and that is put to bed.



Time to put the fender back on...



...then the tire, caliper and chain back on.



Next item on the agenda is the exhaust.

I've had the same idea for a couple of years on what I want it to be. But two things come into play-

1. I can't do exactly what I want because of the rear brake master cylinder. I looked at moving the M/C up front, but did not like that look at all.

I also looked at using a different M/C, but did not want to go that way either.

I even looked at doing away with the foot brake and using a proportioning valve for the handbrake (front and rear), but that is not something I want to do.

2. I've found it is always good to look at things with fresh eyes, not being married to an idea of the past, so today we will entertain every possibility.

Playing with the stock headers...



...one of the first things we discuss is whether to go 2 into 1 or true duals. There is more power to be had with 2 into 1, but this bike is not about making power.

Going with true duals will give a better sound at an idle, something I really like on a carbed bike...



...but a clean 2 into 1 will go with the minimalist look that is the overall theme of this bike. Something like this-



More in next post.

Kevin

[DK Custom Products]

I really like the look of one pipe running along the swingarm...



...it follows the existing line of the bike, and almost disappears along the frame rail.



But the ideal spot for the 2 into 1 is right where my MC is sitting. Here we're looking at two pipes running along the swingarm.



Putting the carb on, then looking at bringing the rear header forward, under the carb, and joining up with the front header...



...nope, that idea is not clean, nor great to have the heat right under the intake.

We look at running the rear header out to the left side of the bike. That is how the True Duals on my Softail run.



What we decided on what getting some new headers to work with. That way we don't need to delete the crossover pipe on the stockers, which will be a pain to get the patch totally smooth.

Then we will run the rear pipe all the way back, along the swingarm, ending a bit past the axle.

On the rear pipe, right behind the M/C, we will put in a 2-1 collector, pointing forward. The front header will marry into that collector, under and inboard of the M/C for the least visible junction of the two.



That's it for now. Next week is another short week. Hopefully we will get some more done on her.

Kevin