The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Styles > Sportster Motorcycle Project
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Active Threads
0 45740-62 & 62A differences?
Last Post: Fridge
Posted On: 1 Minute Ago
Replies: 20
Views: 3,132
0 Need to part with my '59
Last Post: cazz1000
Posted On: 22 Minutes Ago
Replies: 3
Views: 57
0 When Were You Born?
Last Post: hammer6315
Posted On: 26 Minutes Ago
Replies: 331
Views: 78,751
0 Average age of the Ironhead forum users
Last Post: owlsplace
Posted On: 42 Minutes Ago
Replies: 441
Views: 83,312
0 Lowbrow XLR pipes
Last Post: A Seabee
Posted On: 48 Minutes Ago
Replies: 0
Views: 12
0 Question for RB racing exhaust guys/gals
Last Post: 883sporty03
Posted On: 55 Minutes Ago
Replies: 28
Views: 522
0 Efi and carbs
Last Post: Toejam503
Posted On: 58 Minutes Ago
Replies: 32
Views: 564
4 Hello from Chicago
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 6
Views: 90
0 Rear axle - what am I doing wrong?
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 6
Views: 125
0 Can't get the free wiring diagram from HD
Last Post: bustert
Posted On: 1 Hour Ago
Replies: 1
Views: 38
0 Foot peg stud not lining up with motor cut out
Last Post: Thirdbrick
Posted On: 1 Hour Ago
Replies: 4
Views: 56
0 Hi
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 4
Views: 31
1 Pics of pets and what type of animals you have
Last Post: trainman
Posted On: 1 Hour Ago
Replies: 987
Views: 210,065
0 What Petcock
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 23
Views: 2,212
0 Which cams ?
Last Post: Cumofo
Posted On: 2 Hours Ago
Replies: 4
Views: 145
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 2 Hours Ago
Replies: 44,121
Views: 6,910,432
0 Kickstarter return spring
Last Post: JonesL
Posted On: 2 Hours Ago
Replies: 4
Views: 214
0 This week on Craig's list
Last Post: A Seabee
Posted On: 3 Hours Ago
Replies: 4,140
Views: 475,144
0 Hi everybody!
Last Post: big andy
Posted On: 3 Hours Ago
Replies: 17
Views: 196
0 Sell pricing for 1979 XLS IH Sportster
Last Post: RoadsterMike
Posted On: 3 Hours Ago
Replies: 13
Views: 870
0 Broke my drive belt (Stay With The Belt Or Do A Chain Conversion?)
Last Post: motorend
Posted On: 3 Hours Ago
Replies: 70
Views: 19,706
0 Parrothead and the 2019 Iron Butt Rally
Last Post: dieselvette
Posted On: 4 Hours Ago
Replies: 64
Views: 2,863
0 2019 East Coast Meet and Greet
Last Post: mikeLI_77
Posted On: 4 Hours Ago
Replies: 358
Views: 36,879
0 Do you use premium gas in your Sportster?
Last Post: Renecito
Posted On: 4 Hours Ago
Replies: 1,767
Views: 358,074
0 7 Dead and more wounded
Last Post: sportsterpaul
Posted On: 4 Hours Ago
Replies: 30
Views: 1,154
0 Let's See Them R's!!
Last Post: PetesPonies
Posted On: 4 Hours Ago
Replies: 1,535
Views: 566,599
0 Riding in The Heat!
Last Post: motorend
Posted On: 5 Hours Ago
Replies: 25
Views: 640
0 surges and/or hunting on 1200 EFI's
Last Post: Clevspeed
Posted On: 7 Hours Ago
Replies: 99
Views: 26,764
0 Stock Seat 48!
Last Post: Clevspeed
Posted On: 7 Hours Ago
Replies: 2
Views: 173
0 Fantasy Football League
Last Post: Ireeman
Posted On: 7 Hours Ago
Replies: 4,302
Views: 227,953
More...
Members Birthdays
richard rees (70), IRONHD1K (66), derekb (58), Hankrebel (43), CPurner (38), Vickers
Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #1  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Cool Custom Racer with Aluminium Frame and Sportster Engine

Hi Guys,

as it's Winter now business is slow and me and the guys at the shop have some free time on our hands.

We wanted to try something new anyhow already since some time, so we decided to build a bike with a custom made chassis and bodywork.

It'll be certainly quite far away from the "standard" Sportster builds, but I hope you're still interested.

I'm trying to document the build here step by step....

Everything started with an old 2006 model bike...less than 8000 miles on the ODO.
Reply With Quote
  #2  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Default The Donor Bike

That's how the bike looked when we got it....




Reply With Quote
  #3  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Default First Steps

The very first thing we did, was taking the bike completely apart.

We left only the Engine and some components from the electric system, nothing else will be used again.

Then came an important step, of which I don't have pictures (Unfortunately).

We measured up the engine, weighted it, and roughly determined its weight distribution.

Based on these specs, I've sat down and determined the overall specs of the bike we want to build.

We're planning to build a fast Road Bike, as lightweight and nimble as possible.

After some calculations I've came up with the following specs:

Rake 23.5 Degrees
Trail 98mm
Wheelbase 1480mm
Seat Height 825mm
Ground Clearance 245mm
Swingarm Angle 12.6 Degrees

At that time I already made a complete 3D model of the whole bike...But I don't want to show it now here,otherwise I'd just spoil the suprise

Based on the Height of the engine in the Chassis, we've build a small Prop-Table with an adjustable engine holder.




It's an assembly help.

It holds the engine in the same place as it would be in the bike later.

In this way we can start to assemble all the components around it, checking everything for fitment.

Last edited by DM_ANDREAS; 15th January 2018 at 07:34.. Reason: Added Info
Reply With Quote
  #4  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Default Taking Measurements

Then the actual work on the bike started.

You can see here already the forks which we're going to use.

These are GSX-R 1000 Fork Tubes in GSX-R 600 Triple Trees with a GSF 1200 Wheel and Brake Rotors.

I've selected these parts because that combination gives me exactly the specifications I've been looking for.

The big tube on top is only a mock up.

It's a piece of stainless tube which has been cut to size and a Triple Tree Mount has been welded in at the desired Rake.

That assembly has been mocked up at the engine, allowing me to take measurements for the front engine mount.

Reply With Quote
  #5  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Default The Design Work starts

As I have now the reuired measurements for the front engine mount, the first few components could be designed.

The very first part is the steering head and front engine mount.

Here are some screenshots from my 3D models.





These are 2 parts, which are bolted together.

Both are CNC cut out of a solid block of Aluminum.

The steering head is also hollowed out from the rear, to save weight.

Why cutting these out of a solid block?

- It's extremly strong
- It gives you perfect control over the geometry. A welded assembly will never be as precise.
- I've never seen anybody else do it this way...so why not build something special ?!
Reply With Quote
  #6  
Old 15th January 2018
DM_ANDREAS DM_ANDREAS is offline
Biker
 
Join Date: Jan 2018
Posts: 23
Sportster/Buell Model: XL12000
Sportster/Buell Year: 2006
Reputation: 17668
DM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to allDM_ANDREAS is a name known to all
Default The CNC is running again

Once I've finished the design the guys at our shop machined the parts for me.

Here are some pictures from the process.

First the Steering Head...








Now the front engine mount...





Reply With Quote
  #7  
Old 15th January 2018
XL Ed's Avatar
XL Ed XL Ed is offline
XL FORUM TEAM MEMBER
 
Join Date: Dec 2009
Posts: 1,797
Sportster/Buell Model: XL1200R
Sportster/Buell Year: 2004
Reputation: 1556875
XL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond reputeXL Ed has a reputation beyond repute
Default

Looks cool. Can't wait to see more progress.
Reply With Quote
  #8  
Old 15th January 2018
Flame__'s Avatar
Flame__ Flame__ is offline
Artist, rider, wrencher
 
Join Date: May 2007
Location: Harlem, Ga
Posts: 4,723
Sportster/Buell Model: 1200 (Bruiser)
Sportster/Buell Year: 1989
Sportster/Buell Model #2: 883 (Fiona)
Sportster/Buell Year #2: 1988
Other Motorcycle Model: FLHTC (Ruby Lee)
Other Motorcycle Year: 2000
Reputation: 3294333
Flame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond reputeFlame__ has a reputation beyond repute
Default

Too cool, man!
__________________
Knees in the breeze.

Gamertag, PS4: Bikerdude__
Reply With Quote
  #9  
Old 15th January 2018
norseXL's Avatar
norseXL norseXL is offline
Senior Custom Bike Builder
 
Join Date: May 2011
Location: Ultima Thule
Posts: 2,849
Sportster/Buell Model: xlh883/1250
Sportster/Buell Year: 1986
Sportster/Buell Model #2: XLH 1200 (Pia's)
Sportster/Buell Year #2: 1994
Reputation: 1762995
norseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond reputenorseXL has a reputation beyond repute
Default

Subscribed!
__________________
"In the design of an internal-combustion engine, as in all creative work of this nature, the æsthetic side must not be overlooked.
In the first place, beauty of form and of proportions is in it self an admirable guide to mechanical correctness;
for mankind has come to regard as beautiful that which is mechanically correct, whether it be in nature, in architecture, or in enginering."

Sir Harry R. Ricardo
Reply With Quote
Sponsored Links
  #10  
Old 15th January 2018
CyclesInc's Avatar
CyclesInc CyclesInc is offline
XL FORUM TEAM MEMBER
 
Join Date: Dec 2015
Location: NJ
Posts: 474
Sportster/Buell Model: A Few
Sportster/Buell Year: many
Reputation: 118394
CyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud ofCyclesInc has much to be proud of
Default

Looks like an interesting project. Looking forward to see how it progresses.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 05:33.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC