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  #21  
Old 8th April 2016
Phelan's Avatar
Phelan Phelan is offline
Senior Custom Bike Builder
 
Join Date: Dec 2006
Location: Fountain, CO
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Sportster/Buell Model: EBR 1190 SX
Sportster/Buell Year: 2017
Reputation: 64602
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Movin' right along! Here I finished reassembling the motor. I was excited and eager to try out DK Customs rocker lockers, but upon reassembling the motor, I realized that I forgot to order them. Not wanting to wait to order some in, I made my own out of some .015" steel. So I should hear a bit less clatter in the top end .



Then I got the swingarm, oil lines, and various bits mounted.



Then I bolted the frame and subframe onto the motor, and after this pic I bolted the rear shock as well. Normally you would want the exhaust mounted before attaching the frame, but I won't get the exhaust for another week or so, and I want to make this a roller. I can do a simple motor rotation to install the exhaust later.



Next, I moved to the front end. One of the pieces I've wanted to use for a while were these Rooke Risers. I cut the lower handlebar clamps off the top tree a while back, and today I filled in the original clutch cable guide hole and drilled 1/2" holes to mount the Rooke Risers.



These risers were made originally for Yamaha cruisers with 1 1/4" fatbars that tapered to 1". Since my OSX One fatbar is only 1 1/8" (standard oversize for 7/8" controls), I made shims out of some perforated steel tubing I had and I glued them in place to simplify installation.



Here's a mock up of the trees and risers.



And what's this?? We have a roller! I installed the new CR forks, put a front tire on the wheel, and mounted it up so the bike can almost stand on its own (still waiting on the SS kickstand). After this pic I also installed the front brake setup with new ceramic pads. I may source a shorter brake line, as the stock Uly brake line is now about 8" too long between the shorter suspension and shorter, straighter handlebars. The clutch cable is a little long, but plenty useable. Really excited to see this coming together..

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  #22  
Old 11th April 2016
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Phelan Phelan is offline
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Posts: 2,565
Sportster/Buell Model: EBR 1190 SX
Sportster/Buell Year: 2017
Reputation: 64602
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I am so close now. I have a new name picked out, and want to keep the rest under wraps for now. I should receive the exhaust and last few bits next week. I'm going to great a new thread when I do complete it, and link it here. Thanks for watching .
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  #23  
Old 12th April 2016
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ChefRex ChefRex is offline
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Sportster/Buell Model: XLCH
Sportster/Buell Year: 1968
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Other Motorcycle Model: XLCH
Other Motorcycle Year: 65
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Looking great! You can install the exhaust with out rotation if you pull the fan out.
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  #24  
Old 12th April 2016
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Phelan Phelan is offline
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Sportster/Buell Model: EBR 1190 SX
Sportster/Buell Year: 2017
Reputation: 64602
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Oh, that's clever. Never thought of that. But I have to put the intake manifold on as well still anyway, since I'm still doing things to it. I'll remember that trick for next time though for sure.
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  #25  
Old 25th April 2016
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Phelan Phelan is offline
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Sportster/Buell Model: EBR 1190 SX
Sportster/Buell Year: 2017
Reputation: 64602
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Things are moving slower than I'd like, because of various reasons- job, weather, later shipping on the exhaust, etc. But if I somehow manage to get out of jury duty tomorrow, I should be able to get it running tomorrow. In the meantime, here's a sneak peak...

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  #26  
Old 4th May 2016
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majam1 majam1 is offline
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Looking good. I wasn't to sure about the yellow but it has grown on me. Hopefully you can post a sound bite of her running!
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  #27  
Old 4th May 2016
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Baby883 Baby883 is offline
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I would say leave it as it is and just ride the thing... Seems to me she spend more time teared down then on the road...

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  #28  
Old 5th May 2016
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Phelan Phelan is offline
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Sportster/Buell Model: EBR 1190 SX
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This project has been long in the tooth, and still not done because of time constraints, but its no trailer queen. I put over 6000 miles on it in 6 months, mostly riding to work and back. The bike sat for 3 years before I got it, and it had 68,000 on the clock at that point. There were things I needed to correct besides the changes I made.we had snow as recently as last Friday, and I ride 4-8 bikes a day at work anyway. But this will be done and out of the garage soon; I have an 03 XB9R in the backyard waiting to get torn down for an 08 XB12 crank setup and 90" kit, among other goodies.
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  #29  
Old 20th May 2016
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Phelan Phelan is offline
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Starting to look like a bike again! Still lots to do, but so much closer now!





I even got this to match

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  #30  
Old 20th May 2016
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majam1 majam1 is offline
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The bike looks awesome Phelan. Sending you a pm.
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