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  #1  
Old 13th March 2020
npaisnel npaisnel is online now
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Sportster/Buell Model: XL883 now 1200
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Default Easy Brackets on 93 Sporty

Years ago I fitted a set of Easy brackets from Leatherworks Inc. with their excellent bags to my 04 Sporty

Just bought a 93 Spory so wanted to fit the same brackets to it...
but no go. No one makes the mounting hardware to fit the Easy bracket mountain posts to the Sportys with the curved rear frame rails.

So I am having to make my own. I am drawing them in a CAD program , and cutting ghtem out on mates laser cutter as wooden prototypes...Once the design is complete and DXF files are correct, I'lllet amy one have them.,and then ally need to do is send them to your local laser / water jet metal cutting ship and get some made up

Also, you will need to buy your own bolts...list to follow ..turn down some mounting extension hardware and modify the rear indicators...


What I have done is removed the original Sissy bar plates that bolt either side, and am in the process of re making them bigger to take the Easy bracket mounting stubs.

A bit of a long job, as it turns out that apart from the fact that the curve means you can't fit the rear 'stub' to the frame, the space between rear shock top mounting bolt and rear light is three inches shorter.



This means the conventional Indicator relocation kits can't be used straight off as you do not get enough space for the bags. So you need narrower relocation kit to get the indicator inside the edge of the bag.

This is the relocation kit I used. I settled on a JP Cycles relocation kit. and only then after it arrived did it find it would not work a it was too wide.


Too wide


But luckily the design is such that the end 'plug' unscrews (Red loctite ! so need heat).



I only found this out after I snapped one.




But luckily I have a lathe, so I turned a new one from (I think 7/16) a UNF Bolt)

So you cut down the old ones, I think I took about 3 inches off each end, re tap an internal thread and fir the old end pieces..or your newly made ones if you snap them!

Now they fit inside the inner width of the bags




I have gone through various designs, of the plates in wood.

Starting form the original side plates with a paper template of the top.


Scanned in to the Computer and drawn in SketchUp
Then laser cut in 3mm ply





Then I decide that I'd try and make it so the Sissy bar can be used in a solo seat or Pillion seat config. When in Solo sissy bar config, also allows to fit a rack where the pillion seat would be.

I started by making the template with the sissy bar pieces fixed...not for th final design, but merely to ease cutting out and initial design.




Originally I used the second hole from the rear shock as in the next pic. but the indicator issues meant that i would ideally need to move it forward.



But I realised I could use the more forward hold and relocate the rear hole


But this does mean that the rear stud now needs mounting further out, so need to turn done some metal stubs, that sit on the alloy frame cover, to his in supporting the weight

Also needs a little stub in the hole front



I do plan to turn these down some more, to reduce the weight a bit.
The bolts need to be 3 ½ inch, the rear one possible a coach bolt with a square shank pushed through from the fender side.

Todays mockup I have now removed the sissy bar brackets and made holes along the side plate rails.
Sissy bar bracket can now be mounted front or rear. and the other hoels will be used for rear rack mounting when there is no pillion seat fitted.







Still need to tinker with the wooden design, make the holes line up better, and decide if I want to keep or remove the "fish tail ' end piece.


Still need to design a rack too..


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  #2  
Old 1 Week Ago
npaisnel npaisnel is online now
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Default

OK, so after all these months and about 28 re designs cut in wood and tested out ..finally did a cut in 3mm 316 stainless steel.

All fitted up, but not happy with the result..it works with a bit of tinkering, the plates tend to bend so the rear stubs/posts sticking out for the brackets are not parallel..therefore too wide at the tips.

Had to drill the fender too, as even the thin 'jam' nuts for the rear posts were going to foul the fender, if i tried to keep the nuts outside. The downside is the pressure does distort the fender a bit.

Would have been nice to have fitted the rear posts with 3/8th x 24 TPI UNF bolts so I could have threaded the plates. I did initially thread the plate for the UNC 18 TPI bolts but not many threads in 3mm. I could not find a supply of 316 grade ⅜ x 24 TPI bolts in allen head and 3 inch long..so had to settle for 18 TPI UNC

Maybe welding the rear post studs to the plate would be the way to go.












Last edited by npaisnel; 1 Week Ago at 09:37.. Reason: Spelling and typos.
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  #3  
Old 1 Week Ago
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Highly-Dangerous Highly-Dangerous is online now
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Default

Good effort mate!!! you'll get it right.

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  #4  
Old 1 Week Ago
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Default

Amazing, thank you for your determination!
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  #5  
Old 1 Week Ago
npaisnel npaisnel is online now
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Default

Edited my previous post ..as now I am on a computer i can see the raft of types that I missed when posting from the phone.





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  #6  
Old 1 Week Ago
npaisnel npaisnel is online now
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Default

Original idea was just to make the plates the same as the original items with them made just a bit bigger to take the rear lug..but I got carried away...


I have the CAD files here for free if any one wanted to get some made locally.




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  #7  
Old 1 Week Ago
npaisnel npaisnel is online now
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Default

I will probably weld up the brackets that fit on the rail..those small No.8 (5/32) set screws were originally just going to be for holes for pins to make alignment easy for welding up any way.

Also have made some risers to fit those rails..so i can eventually make a rack too that sits where the pillion would be.


The edges of the metal work, is unfinished, straight off the water jet cutting table. Will need the edges slightly softening, as they are razor sharp, and will run them over the polishing wheel too, to make them look a bit neater..but not login to go mad!



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  #8  
Old 1 Week Ago
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Default

Fantastic work!
Thanks for sharing the progress.
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  #9  
Old 1 Week Ago
npaisnel npaisnel is online now
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If I had done it 25 years ago I could have made money out of em !
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