The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > Blogs > Big Al
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Notices

Active Threads
0 Recent 1275 Dyno Tune
Last Post: rocketmangb
Posted On: 51 Minutes Ago
Replies: 15
Views: 147
0 ....1
Last Post: Highly-Dangerous
Posted On: 2 Hours Ago
Replies: 5,597
Views: 325,000
0 KT - 2020 - Where Eagles Dare
Last Post: IXL2Relax
Posted On: 3 Hours Ago
Replies: 52
Views: 10,541
0 Sportster Fork Upgrade
Last Post: PetesPonies
Posted On: 4 Hours Ago
Replies: 85
Views: 16,363
0 Keep & Kill
Last Post: Crusty
Posted On: 5 Hours Ago
Replies: 17,590
Views: 1,020,094
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 5 Hours Ago
Replies: 47,793
Views: 7,661,498
0 73 XL 1000 Sportster - SOLENOID BYPASS
Last Post: 4th of July
Posted On: 5 Hours Ago
Replies: 6
Views: 177
0 theNeckerCube's Problems (Exhaust, Carb, … ?)
Last Post: sportsterpaul
Posted On: 6 Hours Ago
Replies: 2,451
Views: 157,394
0 Mid Glide width?
Last Post: sml1226
Posted On: 6 Hours Ago
Replies: 0
Views: 25
0 How many miles do you have on your rubbermount?
Last Post: sportsterpaul
Posted On: 6 Hours Ago
Replies: 466
Views: 92,874
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 6 Hours Ago
Replies: 20,213
Views: 2,064,095
0 Iree's late night cafe
Last Post: NLXL
Posted On: 6 Hours Ago
Replies: 1,605
Views: 214,211
0 Roads I'd like to ride.
Last Post: Graywolf
Posted On: 6 Hours Ago
Replies: 3,133
Views: 292,099
0 Can’t go over 70mph
Last Post: Davo_137
Posted On: 6 Hours Ago
Replies: 11
Views: 246
0 How many miles are on your sporty?
Last Post: sportsterpaul
Posted On: 6 Hours Ago
Replies: 1,217
Views: 319,444
0 Oh these college kids
Last Post: NLXL
Posted On: 7 Hours Ago
Replies: 19
Views: 1,871
0 Parts
Last Post: NLXL
Posted On: 7 Hours Ago
Replies: 7
Views: 239
0 Hot Chicks on Hot Bikes
Last Post: trainman
Posted On: 7 Hours Ago
Replies: 10,825
Views: 2,077,941
0 ooops
Last Post: roadmut
Posted On: 9 Hours Ago
Replies: 0
Views: 54
0 You asked for it! "The Tess' Coffee Thread"
Last Post: Ireeman
Posted On: 9 Hours Ago
Replies: 11,059
Views: 1,006,311
0 Hot Rods, Rat Rods, and Customs.
Last Post: Maxeffort
Posted On: 9 Hours Ago
Replies: 4,120
Views: 582,809
0 Shovster build take2
Last Post: RicThompson
Posted On: 9 Hours Ago
Replies: 24
Views: 699
0 Rubber mount gas tank part
Last Post: IXL2Relax
Posted On: 9 Hours Ago
Replies: 3
Views: 232
0 ultima install without VOES
Last Post: ryder rick
Posted On: 9 Hours Ago
Replies: 8
Views: 216
0 Current projects (2 of them anyway)
Last Post: Ferrous Head
Posted On: 10 Hours Ago
Replies: 54
Views: 2,122
0 1972 Build thread please subscribe
Last Post: brucstoudt
Posted On: 11 Hours Ago
Replies: 79
Views: 5,245
6 Blast Project (and will be needing help most likely)
Last Post: rokytnji
Posted On: 11 Hours Ago
Replies: 102
Views: 18,754
0 Now running 3.40 factory gearing
Last Post: cliffm
Posted On: 13 Hours Ago
Replies: 1
Views: 78
0 Yearly Allotment of Miles
Last Post: Bigshankhank
Posted On: 14 Hours Ago
Replies: 14
Views: 308
0 Headwork
Last Post: ericfreeman
Posted On: 14 Hours Ago
Replies: 3
Views: 168
More...
Members Birthdays
mbsales (73), loopback (61), HHahn001 (51), NHXJer (46)
I will keep a carbon copy here of all my blog posts on my personal Cycle Blog @ http://mast3r7.blogspot.com/

XLForun.net only allows 4 pictures per blog post, so to see all of the images and details of posts, follow the links to http://mast3r7.blogspot.com/

I will write not only about what is going on with my current Sporty Project, but also about Lifestyle and HD ownership as well, enjoy.

-Big Al
Rate this Entry

Fender Cutting & Tail Light Removal

Submit "Fender Cutting & Tail Light Removal" to Facebook Submit "Fender Cutting & Tail Light Removal" to Google
Posted 28th June 2010 at 14:22 by Big Al-1200c

Fender Cutting & Tail Light Removal

!The XLFORUM.net blog only allows 4 pics, to see all of the pics in detail, please click the link above to be taken to the original article.!

Now that the Run, Stop, Turn Signal Module has been installed, we move into cutting the fender.


Here is the digital muck-up I did, trying to decide where to cut the fender.


I removed the fender to remove the tail light and move the wiring and support bracket out of the way.

(IMAGE)

This is the Tail Light Base that contains the Circuit Board we need for later. Disconnect the wires and carefully pry it outwith your hands or a wooden tool.

(IMAGE)

Note on the picture to the right, that the fender support bracket and harness are in the way of the cutting line. The harness was moved back and will be relocated later, the bracket on the other hand, since I want to retain it for 2 up riding support, needs to be moved.

(IMAGE)

To do that, just flip it, so that it hangs towards the front of the fender instead of the rear. Now the harness support tabs notches are in this new location, preventing the bracket from laying flush against the fender.

(IMAGE)
A quick cut with the dremel and that is taken care off.
Now the bracket can lay flush against the fender.

(IMAGE)

Stand back, I have not dusted the ol' Dremel in a few years! (and I call myself a man?), so my hands are a bit rusty. I have to say I recommend a 3" cutting wheel instead of the Dremel, as that will probably take 5 minutes, took me 25 minutes with the Dremel. Use blue painters tape or similar to protect the cutting area, making sure it is tight and without bubbles. Use a pencil to mark your cutting line and measure to make sure you are even. All up to this point, you can change your mind and go back, but once you put the dremel to the fender you are committed, so make sure you got the line and contour where you want it. Once done, I used a stone to remove sharp edges and even out any imperfections.

The cut came out clean and straight.


(IMAGE)(IMAGE)(IMAGE)

Up next,
License Plate Relocation
Mounting the circuit board under the fender, plus routing the wires.
Paint

-Big Al
Posted in Uncategorized
Views 12501 Comments 2
« Prev     Main     Next »
Total Comments 2

Comments

  1. Old Comment
    Epyx's Avatar
    Good post, thanks for the effort. I am going to use this in the future. Not on my XLN but on a Yamaha project bike I may start working on some day.
    Posted 7th July 2010 at 11:49 by Epyx Epyx is offline
  2. Old Comment
    this is a great blog I'm going to be doing the same hing to my 883 thanks for the info
    Posted 18th May 2011 at 14:19 by rikasso
 


All times are GMT +1. The time now is 08:45.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC