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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #121  
Old 30th April 2019
ex119x ex119x is offline
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Paul, I have 7/8 bars on my 73. I used the stock clutch lever setup from an 86 Yamaha FZ600. It worked with the IH cable, with a little modification to the barrel end of the cable. I also used switchgear from the same model as I have a whole box of that stuff leftover from my racebikes.
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  #122  
Old 30th April 2019
paulc paulc is offline
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Quote:
Originally Posted by Flame__ View Post
Paul, I swapped the 2,25 peanut on my 89 to a 3.3. It was longer. The 2.25 left a space between the tank and the seat that the 3.3 covered.
Interesting, thought they were just wider. The tank on my 76 is the larger type but still too short really, ideal otherwise so that gets me thinking.....

Quote:
Originally Posted by ex119x View Post
Paul, I have 7/8 bars on my 73. I used the stock clutch lever setup from an 86 Yamaha FZ600. It worked with the IH cable, with a little modification to the barrel end of the cable. I also used switchgear from the same model as I have a whole box of that stuff leftover from my racebikes.
I'm planning on running the hydraulic clutch setup that yoshi devised, still good to know what fits though.
What are you using for the throttle assembly on the 7/8th bars?

Now the battery tray, electric box and swingarm brace mockups are done next job is looking at the rear master cylinder setup. I have my 76 to copy, will do more or less the same as I did on there. I can do that all myself except for a small spot of welding it needs.Work in progress:



The guy who does my major fab work and welding is away for a few weeks so I'm preparing everything I can for when he gets back so I can take it all down as a job lot.
Paul
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  #123  
Old 5th May 2019
ex119x ex119x is offline
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I just have some generic single cable throttle on it that I had left over from one of my roadracer projects. It was in one of my spares parts boxes that I have of that kind of stuff.
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  #124  
Old 29th May 2019
paulc paulc is offline
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Bit more progress lately. Cardboard templates for battery tray and electrics box have gone off to be copied in metal. After much pondering about fuel tank I finally decided to go for a king sportster type tank - lengthened by 2 inches as when I offered up the tank from my 76 it looked good overall but a bit short. That's away being done now, and the swingarm is away having the brace added.
Couldn't think of anything else that needed welding to the frame so bit the bullet and dropped the engine out again. Spent a lot of hours cleaning off the old paint then etch primed it and sprayed gloss black on - Simoniz Tough Paint. Also did the fork yokes and the cover that drops over the top steering stem bearing. Will do various brackets etc the same as well.
Not a professional job by any means but wanted to do the frame paint myself and quite pleased overall. Had to spray in the open in my backyard but think I managed not to get bugs or leaves on it as it dried:



Now I will ignore it for a couple of weeks or so to let it cure as well as it can before dropping the frame back over the engine.
Not 100% sure yet what colour fuel tank. oil tank, side panel, monoshock spring & mudguards will be, either British Racing Green with some silver and black striping, or grey with some red striping.
Paul
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  #125  
Old 13th September 2019
paulc paulc is offline
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Had to wait quite a while to get the fuel tank and swingarm back, finally making some progress again. Got the motor back in the frame again while waiting.

Had the king sporty tank lengthened by 2 inches. Once I got it back I had to figure out the rear mounts. Used the old seat mount under the frame. Cut out some mounts and had them welded on:



Pleased with how things look, that extra 2 inches makes a big difference as the Actress said to the Bishop. Here's before and after:



Pleased with the swingarm, should be much stronger and like the new look. Painted it black, added some vinyl pinstripe then fitted it:



Front end is hopefully on to stay now.Brake & clutch lines ordered, clutch slave cylinder fitted, Amal throttle and S&S E carb fitted, have a temporay throttle cable on to help work out exactly what I need. Made up a coil bracket and fitted that.
Had a few parts powder coated red and have been playing with vinyl striping.
Currently working on rear brake setup then will start on the seat base. This is how things look today:





Still a long way to go but 3 years into this thread it's starting to look like a motorcycle at last
Paul
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  #126  
Old 4 Weeks Ago
paulc paulc is offline
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Nice ride on my 76 yesterday. Pouring down here today though so got a few hours in on the project. Alternator fitted. Rectifier fitted as well. Mount holes were frustratingly close to the distance between the tapped holes at the top of the front frame tubes but not quite the same. A bit of nervous and careful work with a round file on the rectifier and it fits Made up a horn bracket and fitted that too:



Waiting on some welding for the back brake arm but front brake and clutch lines arrived. Almost fitted but still need a bracket for the crossover line:



Oil tank and filter mounts mostly sorted. Had a throttle cable made up and air filter cover is back from chrome stripping and powder coating:





Battery tray and electrics box still not done but making progress.
Paul
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