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  #1  
Old 2nd March 2013
DonChicago48's Avatar
DonChicago48 DonChicago48 is offline
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Default Building a 90-inch Sledge Hammer

I got some good news recently. I talked to Dan at Hammer Performance and my engine work will soon be completed. I'm looking forward to assembling it and getting it started so I can ride again.

I'm about to assemble an '03 1200 engine that will have 90 cubic inches (1474 CC) displacement. The Axtell Cast Iron Cylinders have a 3.875" bore, the largest bore diameter supported by a stock Sportster. It uses reverse-dome pistons with 30-degree squish area and 10.9:1 compression.
The '04-'06 heads have the Hammer Performance Sledge porting with 1.940/1.615 Intake/Exhaust valves and competition springs, retainers, and keepers. The engine is set up for a Hammer 600 cam set, but by shaving the heads approximately .030", it will support the Hammer 660 cam as well. It is equipped with the earlier pinion gear so installing the 660 cam should entail only modest changes.
The engine will be fed by a Mikuni HSR48 carb through a Hammer Performance intake manifold for now. It will use my existing Arlen Ness Big Sucker II Air Cleaner.
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  #2  
Old 2nd March 2013
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NI-STR NI-STR is offline
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Hope your current seat is a deep bucket. Your gonna' need it!
Should be a "ton o fun"!
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  #3  
Old 2nd March 2013
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Good stuff!

If you'd like I can probably shoot some engine porn pics for you, I'll be at the shop today.
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  #4  
Old 2nd March 2013
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Quote:
Originally Posted by aswracing View Post
Good stuff!

If you'd like I can probably shoot some engine porn pics for you, I'll be at the shop today.
We all like porn..
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Late 87-883 Hugger/1380cc (84") conversion. Too many cool parts to list. Built engine on a fresh set of cases, so conversion might not really describe it. Estimated near 115 hp.
Early 87-883/1200 conversion. Wife's bike. SE heads, 1200 flat pistons, 40" Drag Pipes, everything else stock.

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  #5  
Old 2nd March 2013
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Pictures would be good.

Trick heads and pistons with a 10.9:1 compression ratio and a HSR48 sounds like you ain't fooling around.
What year(s) did they use that pinion gear? Is it OEM or aftermarket?
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  #6  
Old 2nd March 2013
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Originally Posted by NI-STR View Post
Hope your current seat is a deep bucket. Your gonna' need it!
Should be a "ton o fun"!
After this build, this will be one of the fastest bikes I've ever ridden. The seat does provide good rear support and I've not skimped on the suspension, brakes and drive train.
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Old 2nd March 2013
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Quote:
Originally Posted by aswracing View Post
Good stuff!

If you'd like I can probably shoot some engine porn pics for you, I'll be at the shop today.
Yes Aaron please do. I have looked through your vast list of engine photos and not found a set of heads quite like mine. Mine have 1.940/1.615 valves, dual spark plugs, and 30 degree squish milled for the 3-7/8" bore.
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Old 2nd March 2013
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Quote:
Originally Posted by Sleeper View Post
Pictures would be good.

Trick heads and pistons with a 10.9:1 compression ratio and a HSR48 sounds like you ain't fooling around.
What year(s) did they use that pinion gear? Is it OEM or aftermarket?
The Sledge 660 cams are made for the 91-99 pinion gear only. This is common among bigger cams as the 91-99 has bigger, presumably stronger teeth. So you look at the big grinds from Andrews, Wood, RS, etc, and they're only available in the 91-99 pinion design.

The Crush 600 cams are available in either the 91-99 or 00-up style. Don't just planning for the future by doing the motor with the 91-99 style right off the bat.
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Old 2nd March 2013
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Quote:
Originally Posted by Sleeper View Post
Pictures would be good.

Trick heads and pistons with a 10.9:1 compression ratio and a HSR48 sounds like you ain't fooling around.
What year(s) did they use that pinion gear? Is it OEM or aftermarket?
I believe it was used from '91-'99. If I recall, the downside to running the earlier gear is that those pinions came in various sizes so ideally, the pinion and cam gear should be fit together to match. I suspect the older gears are a bit noisier as well.
I'm not planning to keep the Mikuni carb for very long. I am working on adapting an aftermarket EFI system to the Sportster. That project thread is here.
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Old 2nd March 2013
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It's going to rock. Color me jealous.
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