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

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  #1  
Old 20th December 2009
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Default shovester build begins

Well I guess I've sort of started assembling this machine. It's been over a year since I got the boxes of parts (modified 1980 cases, shovester jugs, shovel heads, stroker wheels, etc). Since then my lifes been a bit in upheaval, I moved to a diferent job, different town where now it is hard to get time to work on the project because I am only home on weekends. But I've been slowly collecting parts and stripping down my '85 to get this thing together. I really wanted to start by putting the engine together but decided to use the cases as they are now (empty and light) to start fitting the engine to the frame.

I discovered the engine mounts for an '82-85 offsets the engine 13/32" to the left of the position for pre 1982 engines. Now I could just use my old '85 engine mount and this '80 engine would fit perfectly but I want to install a kicker in this engine which means using a pre '82 rear engine mount. So I made up a bracket to sit on top of the pingel mount.



with this and some 13/32" spacers I get the engine to sit in the frame. below is how close the primary is to the swingarm (looking from above) - this is after it's been moved over the 13/32" to sit in the '85 position:



Engine cases mounted in the frame. Still a bit of fine tuning with shims to be done, but it this is itoops, didn't get a photo with the pre '82 mount so this is with the '85 rear mount, but it fits the same now)

[IMG][/IMG]

Hmm, pistons sit on top and so does front head with rocker box but the rear rocker box doesn't quite fit. It looks like it might just barely have clearance if it could get in there but no room to lift heads over fire ring.

Here's the whole engine scaled to match the frame and photoshoped in:



Of course I could cut, extend and reshape the frame to make it fit, or, I think if I just dimple in the frame at the rear I can get the rocker boxes to fit in there. By dimple in the frame I mean like the following: heating and pushing in the bottom of the frame so the round cross section on the left becomes like the one one the right.

Bad drawing but that's the general idea. I hope I can have some time over christmas to sneak out to the shop and try this out. Then if it works I can move on to assembling the engine.

Last edited by billeuze; 5th February 2020 at 05:42.. Reason: remove photobucket
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  #2  
Old 20th December 2009
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Badass! We once did an evo-shovel frame, and we just ground out the offending metal, and welded plate stock to fill th hole we made. It was still working last time I saw it. It looked funky, but you really cant see it much with the bike fully assembled.
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Old 26th March 2010
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Default

So, Bill ...? Have you made any progress with the Shovester build? Didnt know if you had and I just lost the thread you were doing it on or something. Very interesting!
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Old 26th March 2010
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Yup....I have not seen a Shovster in ages! thanks for bumping this. Would like to hear about progress. I would have steered toward the frame mods (raising the backbone and a stretch in the neck / down-leg area).
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Old 26th March 2010
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really slow progress. I have short weekends at home to work on it. nothing to show at this point.

I have my crank together now and just waiting till the jugs come back from boring to check con rod clearances before I bolt the cases together. then it should go fast from there. (of course my fast is still a lot slower than some peoples slow).

I'm putting the transmission together now so it'll be ready to drop in as soon as the cases are together.

The indents on the frame worked great for rocker box clearance.

At some point this spring I'll take a week off work which should help.
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Old 27th March 2010
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I had to "indent" my frame on my Superglide, for the same reason: tall cylinders.
It's looking good so far. Keep posting.
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Old 16th April 2010
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Any updates? Just got the link to this thread-very cool-
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Old 17th April 2010
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Default a bit of rake

A littler bit of progress. I got some cheap brand new oem 2" over fork tubes so decided to give this bike a bit more rake. I put some blocks under the front of the frame to mark the frame height from floor. when I still had the old fork tubes in. Then I put on the new forks, cut the down tubes, had my wife balance the bike wile I and heated the backbone just behind the steering head until it got soft and let it sag onto the block. That should make the frame same height off the ground as before. Here is the photo with the before shot right underneath:


This puts the rake at 38 or 39 degrees and 7 inches of trail. Kind of on the outside edge of a usable trail. I hope works alright. I guess I'll find out when I run it. Can always change it again if I don't like it.
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Old 17th April 2010
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yeah could be a little much for just 2 inches of fork extension. But should cruise nice and stable. Or you can always put longer fork legs in, 4 or 6 overs.
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Old 17th April 2010
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Default Starting engine assembly

I've been waiting weeks and weeks to get my cylinders back from the shop from honing, they are finally back. Now I can put the jugs on the unassembled case 1/2 to check for clearances:


Good thing I checked. connecting rod touches bottom of piston sleeve.


Also the pistons touch each other at the bottom so they need a little filing to clear.
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