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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 27th July 2010
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Default Shovster build continued ...

This is just the continuation of http://xlforum.net/forums/showthread.php?t=682824. I thought I'd better end that thread as it is tittled "Shovester build begins" And, well, even though sometimes it seems like I'm still just beginning, It's actually been over 7 months since I started working on it so it doesn't really qualify as "beginning" any more.

The last post in the previous thread was 2 months ago and well, very little to report. I ended that thread with the exhaust I built. A few weeks ago I finished off the exhaust - welded on the flanges and made a muffler mount. No new photos but it actually just looks the same.

Then over another 2 weekends I got the right side forward controls finished - moved master cylinder up an inward to avoid pavement scraping it and made a brake pedal. I'm pretty happy with the brake pedal, it ended up in the perfect location for me. These started out as Daniel Boone forwards but there's not much left original.





After that I took a break on this project to do some needed maintenance on the old kawasaki I use as daily rider while working on this project.

Finally this past weekend I cut, and reshaped the top engine mount on the sportster frame to make it work with the shovel head engine mount. And while I was at it I welded on the fatbob tank bracket which had until now just been mocked up with hoseclamps:













I still have to add a VOES mounting tab but I need to put the tanks back on the see exactly how much room there is. Hopefully that'll be next weekend when I'm home again.

Last edited by billeuze; 3rd February 2020 at 04:59.. Reason: move from photobucket
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  #2  
Old 27th July 2010
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Default

I seem to remember how this has been done before but not in my recent memory.
Man there is no room above the rear rocker cover.
Looking cool!!
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  #3  
Old 27th July 2010
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yeh, it's not done so much anymore because there are lots of big bore kits available for evos which would be a more logical (simpler & cheaper) way to go. But, I guess I'm not always looking for the most logical way.
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Old 27th July 2010
Fe Head Fe Head is offline
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+1 on the super snug fit of the rear rocker arm/valve cover to frame.

I see a notch missing just above the front portion of the rear rocker/valve cover - are you planning to seal it up and reinforce it back to the wishbone area?

Some time ago I had a exciting speed wobble set in unexpectedly and it turned out to be the back bone was fractured almost exactly at the same spot your notch is.

Possibly there is enough room to wrap a 'U" shaped 12 guage piece up aroung and back to take up the torsion that this part receives from the front end on curves or over a rough set of tracks?

Looks like this one will really pull hard when you're all finished.

Cheers;
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Old 27th July 2010
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Quote:
Originally Posted by Fe Head View Post
+1 on the super snug fit of the rear rocker arm/valve cover to frame.
Just barely enough to get the rear head on and off

Quote:
I see a notch missing just above the front portion of the rear rocker/valve cover - are you planning to seal it up and reinforce it back to the wishbone area?
Yeh, there was a hole through the frame with a small tube going through it. Must have been for some factory mounting option. If I ever did know what the original purpose of that through the frame tube was, I have long since forgotten. When I dented in the bottom of the backbone to make room for the rear rockerbox that tube hole turned into notches. Yes I'm definitely going to fill those notches. That job is on the list of things to do before paint when the frame is stripped and I can easily flip it upside down or any other position to sit comfortably for easy welding.

Quote:
Some time ago I had a exciting speed wobble set in unexpectedly and it turned out to be the back bone was fractured almost exactly at the same spot your notch is.

Possibly there is enough room to wrap a 'U" shaped 12 guage piece up around and back to take up the torsion that this part receives from the front end on curves or over a rough set of tracks?
Yeh, I was thinking of adding some kind of re-inforcement. Now that I hear of your broken back bone incident, I'll elevate that thought to the must do list. The front of the backbone already has some added support from the gas tank bracket but that little piece there behind the top engine mount is the weak spot.

Quote:
Looks like this one will really pull hard when you're all finished.
Cheers;
well, that's the plan. At this point though I won't be able to tell very easily how strong it'll be compared to the old engine. My current frame of reference is the 1983 kz440 that i'm getting around on while building this. I'm pretty used to it by now so even a bone stock ironhead would seem to pull really hard in comparison. At least with this very modest frame of reference I'll be less tempted to disregard the break in period when that time comes - oh, will it ever come?
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Old 10th August 2010
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Default a little progress

just a little more progress:

mounted new oil tank. And I extended the mounting brackets back further so I can lay a tray in there to mount my circuit breakers and a bit of wiring. This way I can keep the wiring up off the fender and see some air between the fender and oil tank.




Also made lower gas tank mount and coil brackets:


The coils fit perfectly in the space in front of the tanks but only in that exact spot. a millimeter out and it doesn't fit anymore - so it took me about 2 days to get the 2 coil mounts fit.




And that'll be it for a while now. Leaving on vacation Wednesday morning. Since I started working on this project the only bike I've driven is my old Kawasaki 440, But next week I'll be renting a sporty (evo though) and touring southern Germany.

Last edited by billeuze; 3rd February 2020 at 05:14.. Reason: move from photobucket
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Old 10th August 2010
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I've got to take my hat off to you , looks like a great project only wishing i had the ability to build some thing as good .
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Old 10th August 2010
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Quote:
Originally Posted by billeuze View Post
just a little more progress:

mounted new oil tank. And I extended the mounting brackets back further so I can lay a tray in there to mount my circuit breakers and a bit of wiring. This way I can keep the wiring up off the fender and see some air between the fender and oil tank.




Also made lower gas tank mount and coil brackets:


The coils fit perfectly in the space in front of the tanks but only in that exact spot. a millimeter out and it doesn't fit anymore - so it took me about 2 days to get the 2 coil mounts fit.




And that'll be it for a while now. Leaving on vacation Wednesday morning. Since I started working on this project the only bike I've driven is my old Kawasaki 440, But next week I'll be renting a sporty (evo though) and touring southern Germany.
Great for the update Bill its all coming together well , I reckon when you get back from Germany I'll be close to slotting Iron Stein into the frame and who knows from there we will be neck and neck to firing these bad boy Shovesters up !!
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Old 10th August 2010
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Great job so far Bill!!! This is a legend in the making...

Are you stopping in to see Bert while you're in Germany???
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Old 10th August 2010
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Thanks for the support you all.

Quote:
Originally Posted by tony t View Post
I've got to take my hat off to you , looks like a great project only wishing i had the ability to build some thing as good .
Sometimes that's what I think too. Like I wish I had the ability to make to make a coil mount in 2 hours instead of 2 days. But this is fun and I'm certainly expanding and polishing my skills as I go along. By the time I'm done I might be able to it right.

Quote:
Originally Posted by Rogotek View Post
Great for the update Bill its all coming together well , I reckon when you get back from Germany I'll be close to slotting Iron Stein into the frame and who knows from there we will be neck and neck to firing these bad boy Shovesters up !!
Well, If you almost have the engine in the frame you're way ahead of me (and you should be with a thirty year head start). I'm still hoping I can get my frame ready to paint before it gets too cold here for that. But yeh, someday we'll both have running shovesters. To bad we're on different continents.

Quote:
Originally Posted by snowman View Post
Great job so far Bill!!! This is a legend in the making...

Are you stopping in to see Bert while you're in Germany???
Thanks for following along Russ. Of course all this wouldn't be happening if you hadn't played your part in the process.

See Bert in Germany. Well I hadn't planned on it. It's sort of a rush trip, only 4 days of unplanned time. There are some prescribed stops and visits along the way and amongst that I managed to squeeze in 4 days of unplanned hanging out at the farmouse with a rented motorcycle which give us the freedom to go wherever the wind blows. Arranging for the motorcycle rental ahead of time is about the extent of my planning in this trip

See you all when I get back, If the camera works we'll have photos too.
Bill
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