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  #21  
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Yeah I'm not looking into frame mods at the moment.
I assumed the distance on top of the boxes to the frame would be pretty close.
But I haven't tried to lift the bottom and the middle together.
The diff being clearance in the back rear side getting over the rockers.
The 86-90 umbrellas are no longer available.
Just wondering how long it will be for the same fate of the 91-03 ones.
I was thinking maybe a 04 Up box conversion but there is a pretty tight clearance even for 3 piece boxes.

Then this thread even more interesting for a conversion, but...........
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  #22  
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Randy_rots Randy_rots is offline
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I was also thinking about fitting PVC XB valves on top of the pre 2004 covers and from what found it would be possible but I never tried it. I have some spare XB PVC valves and I might take some measurements this weekend and report back....
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That'd be great.
I've got to move mine out of the A/C and have been researching the best way for me.
I understand the Buell PCV installs with a grommet.
So if it's just hole that's needed, may be easily doable.
Some holes are complex and some are well...just holes.
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Shame the big tank interferes with the Buell PCV valves. I wonder if one could mod the OE covers and find room for the valves?
Joe
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Quote:
Originally Posted by Randy_rots View Post
The heights are pretty close but pre 2003 rocker boxes are 3 pieces, that's why you can install them in that tight space. XBs and 04 up XLs have 2 pieces rocker boxes and tall covers that won't go between the frame and rocker box base on the rear piece. I was looking into that and It would work but to remove engine from the frame to do that?? Hell no
I am, by my own admission, a complete new guy to Harleys and completely ignorant of HD nuances, but if I correctly read what you wrote here then @Mick42 could never have done on his '05 what the picture he posted picture clearly shows? I think the only way to satisfy it in my mind is to get a set of covers and try it. Too many varied opinions. Covers ordered.... And I guess it matters that mine is a 2000
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Quote:
Originally Posted by Randy_rots View Post
All of them are interchangeable (I mean they will fit). You just can't put XB or 04 up cover on pre 2003 bikes only because there's not enough space between the frame and cover on rear piece.
But if engine is out, it's no problem to fit them. Early 1986 till 1991 I think does not have breather holes, so they won't work on 1991 up models properly.
I have XR1200 heads on my XB 2008 and XB rocker boxes, no problem at all. I only had to plug breather holes.
Also not this topic but you can put XL rocker boxes on Evo BT I have done this once or twice in the past.
This is the correct answer you are looking for. There is no room to slide the rear cover on to the head with the engine installed.

Also The PCV has a long stem that goes down into the umbrella valve/breather chamber (the need to remove the old umbrella valves) so trying to drill the older rockers has to be perfectly above that spot. Not sure if the solid mounts have the room (depth) there and that needs to be checked.
Plus the XB rockers have a machined area around the hole so the rubber gasket seals correctly and if not sealed correctly it’s a place for oil to seep out over the top of you rockers.
Took awhile to remember this stuff and now I’m done.
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That's what I was wondering about the 'complex hole'.
Some grommets have a lip on both inside and outside ends.
So a simple hole is all that is needed to install them.
Some are only lipped on one side with a mating surface needed on the other.
At worst, you could think about using another grommet.
Older V-8 valve covers simply have a hole in them.

The placement of the hole in the cover is irrelevant as long as the holes in the head are sealed up (regular bolt with Loctite would do).
After the head vents are sealed, pressure will find it's way out wherever you put the breathers.
The trick is proper measurement for depth and being on the flat surface on top with the little variance that is there.
The dia of the hole needs to be a tight slip fit.

Measure twice, cut once.
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Randy_rots Randy_rots is offline
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Alright, I took some photos while drinking a beer Saturday night, so please don't complain about quality and stuff .
While doing this, I remembered why I have abandoned my idea of using XB PVC valves on pre 2004 XL. Not that it's not possible, but it's PITA do it properly...
Enjoy the photos.
P.S. DAMN PHOTOBUCKET!!!!












XB cover on top of 2003 XL cover (here's a problem for easy fit of XB PVC valve...

[URL=http://s1281.photobucket.com/user/Randy_R_O_T_S/media/Rockerboxes%20XL%20XB/IMG_4378_zpsoedwvtwb.jpg.html]

XB cover on top of 2003 base (Perfect fit)



XB cover on top of base and middle piece of 2003 XL



XB base on the left and XL base on the right


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  #29  
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OK so the top 1 piece is app equal the top / middle section on 03<.
It doesn't look like it got taller.
I can't remember taking the top and middle off mine at the same time since the top just slides off.

To adapt the breather, need to see one.
The tube length shouldn't be an issue other than the middle box.
If need be, vertical clearance can be had in the mid section by cutting the breather chamber out of one side.
That doesn't ruin the mid section if want to go back to umbrellas since you only need one side and they are symmetric in build.

Does the breather have to be installed flat?
The shelf in the Buell cover is probably just there to help protect the breather position if not.
The grommet press fit should seal the hole.
The shelf (or recess) should just gives it a place to sit without wiggling around.
Here's a post with the drawing.

Quote:
Originally Posted by chrishajer View Post




You can put XB rocker boxes on your bike and use the same style breather. I see you are going to try to modify yours, since one is cracked. You can do that too.

--Chris
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  #30  
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steveolds steveolds is offline
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Wow!!!! Fantastic info Randy! Thanks for the pics. It looks like a very tight fit and maybe impossible, but maybe the cover can be modified or ground to gain some clearance. Thanks for the pics!!!!!!!
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