Harley Ultra Roadsmith Build With Pics

[Cut N Shoot Customs]

This is a 2012 Harley Ultra Classic Limited that we converted using a Roadsmith HDTR kit. The owner, Ron (Santaron1) is from just up the road in Magnolia Texas and is one heck of a nice guy. His nickname is Santa and he does look just like Santa Clause and does a lot of Santa gigs during the Christmas season. This build is from a few weeks ago, but I am just getting around to posting it due to having a lot going on with the flooding at the house.

[Papa Zook]

Uncrating the Roadsmith kit. Ron ordered pretty much every available option, including custom two tone factory match paint, running boards, lighted mud flaps, electric reverse, chrome wheels, chrome bumper, Love Jugs cooling fans, our 9 degree billet rake kit, HD sway bar and auxiliary fuel tank.

[Papa Zook]

The kit comes assembled but has to be almost completely disassembled and the aux fuel tank removed before it is installed, due to the drive belt mating up to the rear drive pulley and the fuel tank being plumbed and wired. This is one of Roadsmith's more intricate builds and is pretty labor intensive...it is straightforward and well designed but not a quicky install.

[Papa Zook]

Pulled the tour pack, mufflers, swing arm, wheel and tire and brake caliper off the Ultra, also pulled the primary completely down and off and re-installed it using the longer drive belt provided with the kit from Roadsmith. The longer belt is necessary due to the longer length of the trailing arm suspension used on the Roadsmith kits.

In the background on the left is our mechanic's really nice springer ironhead bobber getting a complete engine rebuild and on the right a springer ironhead chopper we are rewiring and tuning for a customer. The blue and silver 06 Heritage is in for a trike conversion as well and I will be posting up that build thread next.

[Papa Zook]

OK back to the build: Primary side view..after the primary tear down and new belt install. The rear fender has to be bobbed to fit the trike kit and notched for the aux tank. Thats a loooong belt huh?

[Papa Zook]

This is the rear end subframe assembly and trailing arms which is mounted through the frame/tranny where the rear swing arm was previously mounted and also mounts to the Harley frame. The spring and heim joints are for the adjustment of the electric reverse which will go in next along with differential, axles, reverse, trailer hitch, etc.

Does anyone like build threads?

[Keystone]

Looking good Randy! Love to see build threads!

[clint44]

Man,I love build threads. Bet Ron is getting excited about his new ride. Sure hope he can bring it to Kerrville and show if off.

I'm looking forward to seeing a build thread on that 06 Heritage. Softails make such beautiful trike conversions.

[Papa Zook]

Man,I love build threads. Bet Ron is getting excited about his new ride. Sure hope he can bring it to Kerrville and show if off.

I'm looking forward to seeing a build thread on that 06 Heritage. Softails make such beautiful trike conversions.

I try to post enough pictures and details to give a good idea of how the different trike brands and models go together and show how they are designed and built. Its information everyone needs to see as the engineering and technology on the modern conversions is light years ahead of the factory Harley Trikes.

Ron already has his completed trike back and is loving it. He's had it a while now but Im just getting it posted because I've had a lot going. He says he is planning on joining us in Kerrville and has joined the forum and has already hooked up with some of the local TT members.

The Heritage is under construction now, its together running and driving but waiting on the body and tour trunk to get back from the painter. Its been delayed due to all the rain and super high humidity levels not being conducive to painting. To be a ten year old bike, the blue Heritage looks like brand new. The owner takes great care of it and it shows.

[FuzzyWuzHe]

Looking Good ... I'm sure Ron is thinking about depends right about now ... I know I would be.

[Gorilla]

I like them. It is nice to compare the different designs.

[Papa Zook]

Here is a shot of the rear subframe and trailing arms mounted and the rear fender bobbed. The rear fender has to come off and be slotted to accommodate the fuel breather hose. You can see that although the kit came assembled, it has to be disassembled before mounting the subframe and trailing arm assembly to the frame and then reassembled after the primary drive belt is changed.

[Papa Zook]

Here is a shot of the slotted fender. It is done using a cutoff wheel for the long cuts and a jig saw for the radius cuts. The fender is removed and taped off so as not to scratch it. (even though its hidden under the body)

[Papa Zook]

In this shot of the right rear (from behind) you can see we have installed the differential carrier assembly and differential and the half shaft axles along with the anti-sway bar.

[Papa Zook]

This is a view from the right side looking down, just in front of the tire, showing the aux fuel tank installed, plumbed and wired, the fuel pump installed and wired and the reverse motor and drive gear installed. The reverse motor pivot assembly and cables and handle assembly have also all been installed on the left side and adjusted, wired and tested.

[Papa Zook]

Here is the same view but taken further back so you can see the detail of the mounting points. You can see how beefy the Roadsmith subframe assembly is and how the trailing arms mount to their pivot points. They have been using this same basic design for years but have continued to improve and refine the design so it has evolved quite a bit over the years.

[FuzzyWuzHe]

Looking Good

[clint44]

I really wanted an auxiliary fuel tank before our trike was built but one wasn't available.

Zook,how is that electric reverse different from a H-D unit? I'm not really familiar with the latter.

[1dn5up]

Why the need of the rear fender

[Papa Zook]

Why the need of the rear fender

It's the mounting point for the seat and driver's backrest.