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Spent a good bit of time yesterday and today cleaning out the shop, making room to blow this Sporty apart and have room to organize everything.
Was a big job, had over a years worth of prototypes and take-offs just sitting around. Have a lot of open space now.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Parts%20Space_zpsvrkpg9xx.jpg[/img]
Most of the stuff on those two shelves are going to the DK shop tomorrow...will give me a lot of room to keep everything organized. :)
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Work%20Space_zpstr7defjt.jpg[/img]
Did a bit of work on the Softail...hoping to finish it up tomorrow and get it off the lift.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Getting%20Ready_zps7twah7wt.jpg[/img]
Moved the donor into the shop. Started to take it apart, then remembered that Devin has not ridden it yet in stock form...so I stopped with the removal of the sissy bar and the windshield.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Started_zpsjruxrec0.jpg[/img]
Once it is on the lift I am going to progress as quickly as I can...we'll see how fast that is with all the day to day of running the biz.
Kevin
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Got the Softail done last night. :)
Will be getting the Sporty on the lift today and pull apart as much as I can in the little time I will have later today. :D
Yesterday Devin took a ride on it...
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Devin%20Ride%20b4%20Chop_zpsxlkzxjgc.jpg[/img]
...just to see what it was like before pulling it apart.
First time it's ever been ridden in the rain!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/First%20time%20ridden%20in%20Rain_zpsq7opixk5.jpg[/img]
It has been garaged kept, never ridden in the rain, and averaged 600 miles a year of riding.
[SIZE="5"]Click [B][URL="http://vid1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/SBS%20Before%20Vid_zpsiv0rknu3.mp4"]HERE[/URL][/B][/SIZE] for a quick walk around video of it...sounds really good.
Kevin
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Wanted more time today, but only had 2 hours, but I got a start...
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/1%20on%20lift_zpsk8z2634v.jpg[/img]
Speedo, AC cover, tank & seat gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/2%20Tank%20%20AC%20cover%20amp%20seat%20gone_zpshz4cvawg.jpg[/img]
Coil, fender & headlight gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/3%20Coil%20fender%20amp%20headlight_zps4nppvasd.jpg[/img]
Different angle-
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/4%20Another_zpsrpqic0ar.jpg[/img]
Crazy amount of wires and connectors inside the Riser...
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/6%20all%20will%20be%20gone%20on%20new%20build_zpsfgqidfrr.jpg[/img]
...all this will be gone on the chop.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/5%20Rats%20nest%20in%20riser_zpspalgqczc.jpg[/img]
Battery cover and battery, gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/7%20Battery%20gone_zpsgpsdlcla.jpg[/img]
Risers gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/8%20Risers%20gone_zpsblgpgfli.jpg[/img]
Hope to get a lot more done tomorrow. :)
Kevin
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I did not have anytime on Wed. or Thurs. to work on the bike.
Today I carved out 3 hours and got a few things done.
First was removing the air cleaner. Ran into my first little problem. Someone had either used some red threadlocker, or cross-threaded one of the backplate fasteners into the carb.....AND they know they did it too! The fastener was a full 1/4" from being bottomed out against the backplate.
I drilled it and used and easy-out, but it broke the bolt flush at the carb face. I will deal with getting that out another day.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Carb%20screw%20up_zpsp3vyofei.jpg[/img]
Next was removing all the handlebar controls. After that I wanted to save the fancy HD grip off the left side. Some goo gone and a few minutes waiting, off it came! :)
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Grip%20Removal_zpsc8a3ttjy.jpg[/img]
Next I put painters tape over all the chrome & then removed the heat shields.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Tape%20heat%20shields_zpsqxymr2dq.jpg[/img]
More tape, and removed the horn.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Taped%20up_zpsltlyxinq.jpg[/img]
Next to go were the foot-pegs, brake pedal, slip-ons & headers.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Headers_zpsqu6tc2pm.jpg[/img]
So nice to have plenty of room to put everything as it comes off.
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Stock%20exhaust_zpstjo4fknn.jpg[/img]
Belt guards were easy. Then the next little challenge, the wheel axle had no anti-seize or grease on it at all...it had a bit of rust and corrosion, which made it extremely difficult to remove. A rubber mallet, punch, silicone spray, and a bunch of back and forth to get that spray in there, and tire....Gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Back%20Tire_zpsulhryydh.jpg[/img]
Fender....Gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Fender_zps760ljwrw.jpg[/img]
Swingarm removed (it had some grease on it).
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Swingarm_zpsgybja8it.jpg[/img]
Rear master cylinder and chrome oil tank cover...gone!
[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Swingarm%20cover%20master%20cyl_zpsbi3ui4kh.jpg[/img]
That is where I had to knock off for today.
I'm hoping to get a few hours this weekend and get everything else, except for the engine, off the frame!
Kevin
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Had a bit of time today....Oil tank and battery box gone...[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Oil%20Tank%20Batt%20Tray%20gone_zpseu1wb2a9.jpg[/img]...wiring harness gone.[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Oil%20Tank%20Batt%20Tray%20gone%202_zpsolu4uoxs.jpg[/img]For a carbed bike, this sure is a lot of wiring! And this is not all of it![img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Wire%20Harness%20Gone_zpss4lqb2kb.jpg[/img]Belt and back brake lines gone...[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Belt%20brake%20hose%20gone_zps6grequme.jpg[/img]Had to remove some of my tape job to get the derby cover off, so I could remove the clutch cable.[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Clutch%20Cable%20gone_zps590qlobh.jpg[/img]Derby cover back on, footpeg, shift linkage and clutch cable gone.[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Shift%20Linkage%20footpeg%20gone_zpsz799yzbo.jpg[/img]How I had to leave it today...[img]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Done%20for%20today_zpslgjtrmvw.jpg[/img]...I wanted to get the front end off and get the frame down on the blanket, even had hopes that I might be pulling the engine today. But it was not to be.I should get it down to the frame the next couple of hours that I have. Then will take the frame to the shop and cut it, and weld the TC Bros. hardtail on.Then we get to sit and look at it for a long while, deciding what tabs to cut, what areas we need to fill in and smooth out, fenders, tanks, etc., etc. :)
Kevin
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Decisions, decisionsThumbUp
Its almost like having a blank canvas, for a fabricator/artiste' to create a masterpiece from!
No pressure, Kevin.
The TT "world" is watching;)
Engine internals staying stock at this point in time?
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[QUOTE=peteg59;403777]Decisions, decisionsThumbUp
Its almost like having a blank canvas, for a fabricator/artiste' to create a masterpiece from!
No pressure, Kevin.
The TT "world" is watching;)
Engine internals staying stock at this point in time?[/QUOTE]
Yes, a blank canvas...let's see what we can do with it!
All that's happening to the engine is a Performance Plus Stage I and replacement of the notoriously weak factory clutch pack.
Kevin
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Got it down to the frame today.Removed the carb-
[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Carb%20Removed_zpsndqgibmw.jpg[/IMG]Top engine mount gone-[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Top%20Engine%20Mount_zpsi7to8joo.jpg[/IMG]Ready to remove the front end-[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Ready%20for%20help_zpsojfu18v8.jpg[/IMG]Front end gone, laying it down to pull the frame off the engine-[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Ready%20to%20remove_zps8kst0fck.jpg[/IMG]Last couple of engine mount bolts-[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Unbolting%20Final%20mounts_zpswzsrilzq.jpg[/IMG]Got the frame free of the engine![IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Frame%20is%20free%20of%20engine_zpsswonh9us.jpg[/IMG]That's what needs some major surgery![IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Frame%20ready%20to%20cut_zpsjuf2obzf.jpg[/IMG]Engine set aside for now-[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Engine%20waiting_zpsaflip3gc.jpg[/IMG]
Getting to this point was less than one days work....spread out over a week. Now the fun stuff begins! :)
We have a ton of work going on at the shop right now. It is going to be a few days before we can get the hardtail welded on.
Here's a pic of the TC Bros. Hardtail. Workmanship looks very nice. Very good instructions came with it. When we go to cutting and fitting, I'll let you know how well it all lines up.
[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/TC%20Bros%20hardtail_zpsxk2tw46b.jpg[/IMG]
Pic up next to the frame-
[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Frame_zpsnmoft6i3.jpg[/IMG]
Later this week, after we get the hardtail welded on, that is when the cutting, grinding, reshaping & fabbing up parts will start. While it is only probably a week or two of actual work, it is going to have to be fit between our real work, so will probably take awhile. But I will be updating this thread as we go.
Kevin
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Finally got some time today to get some work done on it!
Fixing to go past the point of no return! :)
Jiffy stand removed...[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Jiffy%20Stand%20removed_zpszqce0ltp.jpg[/IMG]
...marking out where to cut, measuring multiple times before taping for the cuts.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Marking%20where%20to%20cut_zpsoels14j1.jpg[/IMG]
Cutting commences...[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Cutting%201_zpstohafco1.jpg[/IMG][IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Cutting%202_zpsnnscli8d.jpg[/IMG]
And a bit more.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Cutting%203_zpstwx2vkw1.jpg[/IMG]
What we cut off...[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Scrape_zpsceuorvkj.jpg[/IMG]
...and what we're keeping.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/whats%20left_zpsrefgqvtz.jpg[/IMG]
What we cut off weighed 27 lbs...then when you add the swingarm and shocks it is 47 lbs.What was left of the frame weighs 17 lbs.The hardtail section that got welded on weighs 26 lbs.So it was a net drop of 21 lbs., just in the frame.
Drilling the holes for the plug welds.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/drilling%20holes%20for%20plug%20welds_zpsj3ej5cmk.jpg[/IMG]
Got the outside deburred, and powder removed for welding.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/outside%20deburred%20and%20powder%20removed%20for%20welding_zps0o47dslm.jpg[/IMG]
And the inside deburred.[IMG]http://i1088.photobucket.com/albums/i339/DKCustom/SBS%20Sportster%20Chop%20Project/Welding%20on%20Hardtail/Inside%20deburred_zpsnrxesbm1.jpg[/IMG]
More in next post.
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I suck at imagining stuff. I can't wait to see the end result...and I know it's gonna be awhile.