Jeff, without sounding overly regimental, you should try to keep your build in one location and one thread. It makes it easier for yourself in accessing answers to your questions as well as other members trying to give you construction points.
- Was there any unexpected problems in assembly ?
Are you doing an EVO or Twin Cam build ?
The two are similar in construction excepting for the swingarm pivot pin passes through a boss on the rear of the transmission for the Twin Cam and need adequate spacers to fill any voids between frame, swingarm and transmission. Did you read what I said about reinforcing the swingarm?
Also now is the time to consider either raising or lowering the rear suspension while you have the shocks disconnected.
- Was a rake necessary , if so , what about rake bearings and races ?
If you are doing an EVO, you definitely need 4-5 degree rake to reduce head-shake. If you are doing a standard Heritage and not a Springer, you should find a 5 degree Triple Tree. (should come with bearings)
- Are 14" wheels too small for rear..(rear end height )
14" wheels may not clear the disc brake caliper(s). Start with a 15" wheel and a 205/70/15" tire, or a tire with a similar diameter to your stock rear tire. 26-26.5" diameter keeps you speedometer close if the drive is electric (after 1996) This is taking into account you are using the stock pulley diameter too.
- Wide or narrow width of rear tires ?
The narrower the tire with proper air pressure (20-22psi) the better the ride. The wider tire and larger footprint pickup more road feel.
- Is there much power reduction after conversion ?
You are adding weight to the motorcycle and wind resistance with the outboard tires (fenders). It is usually present above 60mph. You can hide that reduction in changing gearing but I would do that afterwards to see if it is really necessary for you.
When installing the rear axle, it needs to be centered and level with the motorcycle. Locate axle from sided to side and square with the motorcycle and belt or chain properly adjusted. DNA axle requires welding of the outer pinch blocks once you get to that point.
Remove the battery ! Make sure all bolts are tightened to spec and tack weld the pinch blocks. Once tack welded remove the rear axle to do the required welding. Jump from top to bottom and front to back so as not to create a warping of the block and go from side to side (L & R) as to not warp the axle tube as well.
I hope you ordered dual disc brakes for your job ???