Zero Trike Build

[Free Bird]

Well, here we go again. I am REALLY enjoying my Freewheeler, but needed something to wrench on myself. So I bought a 2000 TC FXSTS and am going to build a trike...

Here is the donor bike



Here is the concept for the trike



It is modeled after Japan's Zero Engineering's styled "choppers"

There is a LOT to do to make the transformation

I am again working with Doc's, but also with Kool Trikes designers and Just Hawgs in St. Louis to make this all come together. Doc's is helping me dial in the engine, Just Hawgs is doing the frame cutting and welding, and Kool Trikes is providing the rear axle.

Here is the frame concept... Zero "Dragon Neck" rigid reinforced tail section for the Independent Rear Suspension



Here is the IRS... We will eliminate the plate attach points and develop bungs on the frame so that all of the tubes flow together like the frame was designed to receive it from the OEM

Next step.... build the engine

[Zammy]

Wow Jeff, you like to keep busy, looking forward to following the build.

[Free Bird]

The Engine is a Twin Cam that will be taken to 100" via an S&S big bore kit and S&S Performance Heads and an MR103C Cam.

The "fun" part is the carburetion (yes I am running carbs... 2 of them... with two barrels each)... Dual Weber Carbs!

Here is the result...



Here are mine!

I do wonder how the gas mileage will be...

I am also running a 3" Belt Drive on the Primary.... Trying to get an Evil Engineering unit...but will likely go with a BDL with a Dragon Choppers/Crime Scene Choppers Belt guard



The exhaust will be a custom build from Just Hawgs... we dreamed it up after I saw and listened to the Hooker "Fourbidden" header the owner has on his Twin Cam monster bike... it sounded like a Pontiac 455 with open headers!

Here is the standard Hooker Fourbidden



Here is the "Hawg Header" Concept

There are a lot of other mods....Jack here is where you (and others) start telling me what I need to do to build a bullet proof Twin Cam

Anyway...you all get the idea.... so HERE WE GO!!!

[Jack Klarich]

Looks pretty damn cool Jeff

I will be watching

[Gorilla]

Jeff hell of a project. It's going to be fun to watch the build come along.

[Free Bird]

I forgot the Repop 41 BMW headlight nacelle with HD compatible gauges.... The Freewheeler has spoiled me on things like speedo's and knowing if I need gas.... Custom gauge faces and instruments from Speed Hut

[Free Bird]

Well... we are off!

The basic build sequence will be:

Phase I - Build a the engine (as a two wheeler) and dial it in

Phase II - With the engine complete, build the trike in the raw and dial in all of the hard points for the trike conversion (obviously) and oil, hydraulic, electrical...etc....etc. "stuff"

Phase III - Take it down for paint...paint it.... RIDE!

So I started tearing it down yesterday and ordered the initial engine components:

S&S Twin Cam Big Bore Kit to move the engine from 88ci to 100ci that included:

* 4" Bore bolt on cylinder and piston kit (10.5:1 Compression) in Wrinkle Black Finish

* MR103C Cam

* TC3 Oil Pump

* TC3 Cam Plate

* S&S cam chain tensioners

* Quickee Adjustable Pushrods with Tubes

* S&S Precision Tappets

* All parts required to upgrade to gear drive cam

S&S Super Stock 89cc Cylinder Head Kit - I am having it powder coated red cause it’ll look “bitch” as we used to say

S&S Roller Rockers

Sputhe Engineering Forged Rocker Supports

Oil Bud hidden Oil Cooler System

BDL 3” Primary Belt Drive

Tech Cycle 1.7kW Starter

And a bunch of other stuff…. You get the sense of where we are going from the above...

And I have (mostly) defined the venturi and other component tuning to get to the starting point with the Twin Weber set-up thanks to Redline Engineering



Love the look of that thing

So the journey officially has begun!

Looking for some guidance and feedback on the Baker 5 Speed Reverse set up....

Has anybody installed one? What was your experience? I am converting to a hydraulic clutch (sacrilege ...I know) and am trying to decide if I put the reverse on with it. All opinions are welcome...please weigh in.

[Jack Klarich]

What head and base gaskets are you using? You can control your compression ratio with different thick ness gaskets to some degree I like the carb and intake set up, this should give you very good fuel control and quick throttle response

[Free Bird]

What head and base gaskets are you using? You can control your compression ratio with different thick ness gaskets to some degree I like the carb and intake set up, this should give you very good fuel control and quick throttle response

Have not got the gaskets yet, but Cometic will be the brand and I am guessing 0.040 for head gasket the with 100”big-bore kit, but I won’t really know for sure until I measure the piston to deck height. You can't really get the gasket thing right without measuring it.

I am learning about the TC engine via the factory service manual and the web forums. I have read that a good engine builder will tell you 035-040 is the best in a street motor. It will depend on the S&S piston's skirt design's ability to stabilize it in the bore. I can run a 030 at zero deck if there is no piston rock and still allow room for heat expansion of the pistons. But I don’t know any of that until it is measured. Still a long way to go and a lot to discover (for me at least ) in the engine build.

[Jack Klarich]

Before Cosmetic I used copper head and base gaskets. They were much better than stock

Cosmetic are about as good as it gets now IMO

[TonkaDriver]

When I stopped at DK to meet Kevin we talked about twin cam performance. I asked about changing cams for added power. He said that the twin cam has a weak point and it is the crank and adding a cam for more torque would put more strain on the crank. I did some research and sure enough something that performance shops do is weld the crank to eliminate the possibility of it twisting. It may be something to look at for your build.

Kurt

P.S. That trike will be incredible when finished.

[Free Bird]

When I stopped at DK to meet Kevin we talked about twin cam performance. I asked about changing cams for added power. He said that the twin cam has a weak point and it is the crank and adding a cam for more torque would put more strain on the crank. I did some research and sure enough something that performance shops do is weld the crank to eliminate the possibility of it twisting. It may be something to look at for your build. Kurt P.S. That trike will be incredible when finished.

Thanks!!! I love the input. Funny you said the same thing I was told yesterday in a different forum AND by the mechanic that is helping me with the engine build... So I am going with a Dark Horse Crank and Flywheel arrangement ( http://www.darkhorsecrankworks.com/ ). It came highly recommended.

Thanks again... and for all of you reading this.... help a fella out.... if you have a thought or something you think I should check out.... let me know ... PLEASE.

[MDO]

I'm not an engine guy, but I here constant problems with the compensators.

Is that something you have already addressed?

[Free Bird]

I'm not an engine guy, but I here constant problems with the compensators. Is that something you have already addressed?

Thanks MDO. I am planning on a BDL 3" Belt so I hope that eliminates the concern. The end game is a reliable torque monster... So we will address stuff one bad guy at a time

[Free Bird]

I'm not an engine guy, but I here constant problems with the compensators. Is that something you have already addressed?

PS.... I just looked the compensator issue up on "Fix my Hog" and they say the pre-2007 bikes do not have the new compensator that has the main issues. Mine is a 2000. So perhaps I have some insurance

[Free Bird]

Got a bunch of "Stuff" yesterday to do my part for Cyber Monday

* Went with the Motor Trike mechanical reverse

* Baker Hydraulic Side Plate for conversion to a hydraulic clutch

* More engine goodies - Pushrod tube covers, RSD Nostalgia tranny top, rocker boxes, ignition covers

* A cool belt guard arrangement that marries a Dragon Chopper top guard to a Crime Scene Choppers Side guard

* True Spoke Hot Rod 52 16 x 4.5 rear wheels

* Ride Wright 18 x 4 front wheel

* Excelsior Stahl Sport Radial 550/R16 Rear tires & 550/18 front tire

* A pair of unused stretched Flatside Fatbobs for holding gas (They are for early Softail frames, but are going to be modified to mount to the modified "dragon neck" frame)

Next step.... design a small boat tail speedster-like tail section to act as a belt/pulley/differential guard that leaves the shocks and cool IRS components exposed, but which provides a small storage compartment at the rear

More as things progress

[Burnerboy]

Holy shi#,

You lost me on your first post, all I can say is that I'm totally impressed !

WOW!!!



Ronnie

[DK Custom Products]

Your Freewheeler build was inspiring and radical!

Really looking forward to this one.

Kevin

[Free Bird]

Chapter 1 - Donor Bike Tear Down

Well here we go.....

The bike I am converting is a 2000 Twin Cam Springer Softail. We started teardown yesterday with removal of the tank and fuel system components so I could trial fit the twin Weber DCOE Carbs and design/mock up the attach points. I thought I was going to have to develop hard points off the frame, but the kit was well designed. It is fairly obvious that the original kit must have come with a pair of brackets. One that ties into the breather bolts and one that picks up on the top LH case bolt. That is what we are going to do as well. The manifolds bolted on easily and really, they could probably hold the carbs with no additional brackets, but I would rather over engineer than crack the manifold. They look AWESOME!

I worry about the gas mileage though..... NOT!

The twin cam is getting punched out and stroked to 107" with a combo of Wood, Fuel Moto, S&S, Delron, and Dark Horse "stuff" so their will be plenty of displacement for sucking up and using the fuel. Ram air will help a little too . Santa brought me a Motor Trike Reverse kit and a Baker Hydraulic cover for the tranny (gotta love those little elves!)

For those out there saying... "I read all over the internet that those carbs are a pain".... compared to an S&S G? Yep they are much more complicated. BUT once dialed in, they are one of the best carbs in the world. The is why they were OEM equipment on Alfa Romeos, Austin Martins' etc. and they were run on a lot of custom bikes in the 70's and 80's. The 1st issue of Hot Bike (Summer 1971) was devoted to setting up and running these carbs on a 74 Knucklehead and a 1970 STOCK displacement Sportster. Arlen Ness used them on LOTS of his Diggers.... anyway... I know they are a challenge, but who can argue the cool factor of this set up.

So, we are off and running. This project is a collaboration between myself, Randy Butler of Kool Trikes, Doc's HD in St. Louis and Just Hawgs (a great chopper shop) here in town. Unlike the last one, this is a full custom as nearly everything on the bike gets touched in some way.

and PS...

Merry Christmas everybody!!!!!

[DK Custom Products]

Jeff,

Very cool!

This is gonna be fun, just watching from the sidelines.

Merry Christmas!

Kevin