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  #1  
Old 5th February 2013
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Default Airbozo's Sporty upgrade

Not sure what to call this project yet. I am leaning towards a Cafe Racer style setup, but want to maintain a 2-up riding option. I definitely want to get it off the ground a little more.

For now this is just a placeholder to document things I NEED to do and other things I WANT to do.

NEED:
  • Replace my first gear since I am getting some slippage in 1st when accelerating hard (on order).
  • Fix/replace rear fender
  • Cleanup risers (powder coat)
  • New side stand
  • New Mirrors
  • Clean corrosion off all parts
  • Fix the wiring due to some shorts.
  • Behind headlight
  • Backbone
  • Rear section
WANT:
  • New Controls?
  • New suspension
  • Deal with rear plate (side or under fender)
  • upgrade valves (finish head work)
  • Paint engine
  • Rear Sets (this may not allow a 2-up option)

OK, that is enough for now. I will be visiting this list and adding to it. Again, this is really just a project page to keep me on track so I can be ready (hopefully) for Kearney in June.

I will post photo's of those things I think are important or requested.

EDIT: updates will be in red
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  #2  
Old 5th February 2013
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Quote:
Originally Posted by Airbozo View Post





I will post photo's of those things I think are important or requested.

EDIT: updates will be in red
We like photos Bozo.
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  #3  
Old 5th February 2013
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Default

Had half the same items on my upgrade.

Power coating, mirrors, side stand, controls, suspension.

But I went touring.

Don't be a pic tease.
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  #4  
Old 6th February 2013
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Default

Quote:
Originally Posted by Airbozo View Post
Not sure what to call this project yet. I am leaning towards a Cafe Racer style setup, but want to maintain a 2-up riding option. I definitely want to get it off the ground a little more.

For now this is just a placeholder to document things I NEED to do and other things I WANT to do.

NEED:
  • Replace my first gear since I am getting some slippage in 1st when accelerating hard (on order).
  • Fix/replace rear fender
  • Cleanup risers (powder coat)
  • New side stand
  • New Mirrors
  • Clean corrosion off all parts
  • Fix the wiring due to some shorts.
  • Behind headlight
  • Backbone
  • Rear section
WANT:
  • New Controls?
  • New suspension
  • Deal with rear plate (side or under fender)
  • upgrade valves (finish head work)
  • Paint engine
  • Rear Sets (this may not allow a 2-up option)

OK, that is enough for now. I will be visiting this list and adding to it. Again, this is really just a project page to keep me on track so I can be ready (hopefully) for Kearney in June.

I will post photo's of those things I think are important or requested.

EDIT: updates will be in red
For an extra $~100, chainsikle makes passenger peg relocations. They mount to the swingarm, so it should work even if you don't use their rearsets
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  #5  
Old 6th February 2013
Airbozo's Avatar
Airbozo Airbozo is offline
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Quote:
Originally Posted by Stairman View Post
We like photos Bozo.
I will work on photo's this weekend. I'm not at home when it is light out...
I am also a little embarrassed by the condition of my sportster right now. It's been sitting outside under the carport this winter and has some corrosion going on. I will be polishing all of that out as well. I should have enough room in the Harley shed to park it and start tearing it down this weekend as well (purging some computer and construction stuff).

Quote:
Originally Posted by Bob F View Post
Had half the same items on my upgrade.

Power coating, mirrors, side stand, controls, suspension.

But I went touring.

Don't be a pic tease.
I am also thinking about a new frame color. Probably powder coat, not sure yet.


Quote:
Originally Posted by DWilliam View Post
For an extra $~100, chainsikle makes passenger peg relocations. They mount to the swingarm, so it should work even if you don't use their rearsets
This is cool to know. I like the CS rearsets and may go with them.

This is a couple years old, but is what I am starting with:
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  #6  
Old 6th February 2013
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Airbozo,
Just a heads up. The forum will only let you edit a post a certain number of times before that post gets locked. I'm not sure the number but it happened to me on the drag race roll call thread.
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  #7  
Old 6th February 2013
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Default

Quote:
Originally Posted by Airbozo View Post
I am also a little embarrassed by the condition of my sportster right now. It's been sitting outside under the carport this winter and has some corrosion going on.
That makes the makeover look even better. Bad before and great after.
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  #8  
Old 27th August 2013
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Airbozo Airbozo is offline
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Default

Reviving this thread now that I have actually cleaned out the workspace and started tearing down the bike.

I do have a couple of questions for those that have done a complete tear down. I have removed the seat, tank, intake and exhaust. I am now trying to figure out what to take care of next. I eventually want to get the frame powder coated or at least repainted.

I also need to get the motor to the mechanic that will be finishing the top end work.

My question is; "What next?"

Is there a logical method to the tear down? Keep in mind I am somewhat anal about tagging and labeling everything. I have a couple of different sized zip-locks and a sharpie. As I remove parts, I am taking pictures first to show how everything is currently assembled since the manual sucks, taking pictures of all the parts that go together and then putting them in zip-locks and marking what they belong to.

I would like to keep it a rolling chassis for as long as possible, so I know the front end and then tires are last to be removed before I clean up the frame and get it to the painter.

Suggestions?

Thanks in advance guys. This is the first complete rebuild I have ever done so I am learning as I go.

Here are some shots of the beginning;

Before anything is taken off;


In this shot you can sort of see the clearance issues I have with this 89" stroker.


Last edited by Airbozo; 17th January 2018 at 23:42.. Reason: Replaced (insert abusive comment here) imageshack links
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  #9  
Old 27th August 2013
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Airbozo Airbozo is offline
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Bump!

Still trying to figure out where to start next...
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Old 2nd December 2013
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you gettin no love here, eh?

you sound like an organized guy so you are way ahead of the curve.

i just throw everything in a big red tub as i take it off. i wish i could find the bastard that, when i am not looking, throws in all those bonus parts i have left in the end.
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