D.I.Y. Custom Parts w/pics

[hoosier xlc]

Ever get the urge to just make something from nothing?

This is how I spent my Thursday evening. For all who doesn't know, it's an Oil Pump Front Cover from a Big Twin, couldn't find a custom cover for my oil pump....so I made my own!

Here's a shot of the original Pump Cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover010.jpg

It's gonna start with the T6061 Aluminum that I had already face milled and drilled a couple holes in before I got around to start snappin pics.

The Aluminum with the cross holes and a face cut.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover011.jpg

Mounting holes being drilled.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover013.jpg

Oil Cavities being milled.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover017.jpg

Oil Cavities in.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover019.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover021.jpg

Set up to drill Feed and Return Passages, these will drill into the cross holes in the face.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover022.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover025.jpg

Alright now that all the Oil Passages and Mounting Holes are in we will start profiling the Pump Cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover026.jpg

Putting in a few Radius cuts.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover027.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover028.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover030.jpg

The Profiling continues.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover031.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover032.jpg

Starting to become somewhat recognizable.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover034.jpg

Add a few Ball Mill Accents and give myself a reference line to finish the profiling.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover038.jpg

The rest of the profiling was done by cutting the excess off in the bandsaw and finishing the Radius' with the belt sander.

The Cover is still rough as I need to wet sand and Polish it yet.

Here's a shot of the new cover compared to the old cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover001.jpg

Gasket fits properly.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover008.jpg

Side shot
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover002.jpg

Another comparison
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover006.jpg

Let's remember this is still rough, it needs wet sanded and polished before it is done. I will start the polishing process this weekend and toss you all a few final finished pics, just wanted you to see the process so far.

Here's a few more pics for ya.

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover005.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover004.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover007.jpg

That's all the pics I have until the Cover is Polished and finished.
Hope all of you enjoyed the pics and process.

[langner91]

I love it!

[Jackster]

Out of nothing my ass. That's obviously more than nothing. It must be nice to have such materials and equipment at your disposal. It looks really good.

I made this out of some scrap sheet metal and fake leather:
http://i81.photobucket.com/albums/j212/hooddub/P1040703-1.jpg
http://i81.photobucket.com/albums/j212/hooddub/P1040704.jpg

It's not pretty but it's functional.

[jamez1965]

Looks cool - although the DIY part is a bit misleading. :laugh

Edit - why polish it? I bet it looks great raw.

[hoosier xlc]

Why polish it?

Cause if you're going to do something, don't do it half assed.... nah seriously gonna polish it to match the rest of the pump. The old pump had so much paint on it that I had to chisel the cover off, not hard chiseling just enough to break the seal. Polished the Pump Body, and want the Face Cover to match the Pump Body.


Jackster,
That seat flows nicely with the lines of the bike...good job!

[jessearias]

Beautiful machine work my friend!:wonderlan I like it!:clap

[66impala]

I do alot of my own DIY work, but nothing to that Caliber. Very impressive having that skill and ability. Nothing like going to the local watering hole and hearing guys talk about how they put chrome bolt covers on themselves, and you can point to a part like that. Puts it all in perspective.

[milmat1]

Good Work Dude !!!

[misterT]

Very nice! wish I had my own knee mill at home. i can use the machines at work but it is hard to get things done there.

[Sportster1200]

Looks good. If I had a mill & lathe & a lot more experience than I have now I would never leave my garage.

KongBastard

[hoosier xlc]

Nothing like going to the local watering hole and hearing guys talk about how they put chrome bolt covers on themselves, and you can point to a part like that. Puts it all in perspective.

I usually just listen and let them believe what they want.:)

Very nice! wish I had my own knee mill at home. i can use the machines at work but it is hard to get things done there.
I know how ya feel man, since I am on call at all times I have a key to the shop and can come and go as I please, another great thing is I live about 2 1/2 miles from work. Been doing this trade for 15 years this year all with the same employer, they don't mind me making trick parts, they actually think it's kinda cool.

[emzdogz]

I am beyond geeked....
gorgeous piece...

[Rick1590]

looks good Dude...change your coolant, looks pretty nasty! Milltronics Mill? Conversational or G code? It' nice to have that at your disposal! I have a Boss who lets me machine stuff after hours...It's awesome!

[mk2wilson]

Here is my question? Pretty much just food for thought, but it looks to me like in the picture with the gasket, that your gasket is covering up half of the hole that you drilled. I believe it is a oil passage hole, but would have to look at the original again to know for sure. Maybe able to trim the gasket, not sure, but it may be something to look at. It is obvious that you know what you are doing, but I just thought I would point it out.

[hoosier xlc]

looks good Dude...change your coolant, looks pretty nasty! Milltronics Mill? Conversational or G code? It' nice to have that at your disposal!

Coolant is Maintenence mans responsibility, but yes it needs changed. Not G codes or M codes or conversational, just a Supermax Knee Mill with a DRO. Wow, I didn't know we had so many Machinists in here, how cool is that?:banana

[hoosier xlc]

Here is my question? Pretty much just food for thought, but it looks to me like in the picture with the gasket, that your gasket is covering up half of the hole that you drilled. I believe it is a oil passage hole, but would have to look at the original again to know for sure. Maybe able to trim the gasket, not sure, but it may be something to look at. It is obvious that you know what you are doing, but I just thought I would point it out.

It's the same on the factory cover. Not an oil passage there, that's an oil cavity, the 2 holes on top are the oil passages.

[Stingray]

It's not pretty but it's functional.


I'm not sure how functional it really was. I heard you complaining last week about it!



(just messing with you)

[Rick1590]

It always helps to be a machinist or no one when you own a H-D. Parts are much cheaper when you can build them yourself! You could buy the cheap ones that start with something like Kur...but it wouldn't be Milwaukee steal anymore...Would it?

[hoosier xlc]

mk2wilson, here's a pic of the original cover with the gasket on it.

http://www.bikershangout.com/gallery/data/500/medium/pc001.jpg

[debster]

Dang! That's some fancy equipment you got there. Nice job!

[HrdlyDangrs]

Here's my home made Lower XLCH Oil Tank Mount.

Material: Aluminum scrap
High Tech Tools List: Ruler, scribe, hacksaw, file, drill, drill bit, counter sink and large vise

:smoke Hrdly

ps...you can have all the high-tech tools in the world, but without the knowledge/training to operate them, they're just fancy hammers.

Great job on the machine work hoosier xlc

[hoosier xlc]

Hrdly, damn fine job on the tank mount, you gonna leave it brushed alum look?

http://www.xlforum.net/vbportal/forums/attachment.php?attachmentid=14028&d=1202526788

[Hot Rod Sporty]

Great work, Hoosier! :clap

I'm jealous of your shop!!! I wish I had access to your tools.

[AussieGazza]

Beautiful work.

I have a combined lathe/mill and now I am thinkin.....

[mk2wilson]

mk2wilson, here's a pic of the original cover with the gasket on it.

http://www.bikershangout.com/gallery/data/500/medium/pc001.jpg



Cool, I always just try to be suspisious. I am a engineer in the coast guard, so my first thought is always " what is going to go wrong"

[mk2wilson]

I don't think that I mentioned that it looked great though!!!

[hoosier xlc]

Cool, I always just try to be suspisious. I am a engineer in the coast guard, so my first thought is always " what is going to go wrong"

No sweat, I deal with multiple Engineers on a daily basis, I know the feeling you speak of. If there were any doubt in my mind it wasn't right, I wouldn't put it on my bike that's for sure. I machine alot of Hydraulic Valve Bodies, so this was right up my alley so to speak.

Let's remember it's not completely finished, I still have to Polish it and tap the oil ports (waiting on the tap to come in, have all this fancy stuff and was out of an 1/8-27 NPS tap..go figure!), I will toss up a couple more pics when it's finished and on the bike.

[mk2wilson]

No sweat, I deal with multiple Engineers on a daily basis, I know the feeling you speak of. If there were any doubt in my mind it wasn't right, I wouldn't put it on my bike that's for sure. I machine alot of Hydraulic Valve Bodies, so this was right up my alley so to speak.

Let's remember it's not completely finished, I still have to Polish it and tap the oil ports (waiting on the tap to come in, have all this fancy stuff and was out of an 1/8-27 NPS tap..go figure!), I will toss up a couple more pics when it's finished and on the bike.



The one you need is always the one you don't have. I think it looks great the way it is. I too would probably polish it, but it looks fantastic. Now I know who I will have to PM when I have some machine work that i want to do.

[HrdlyDangrs]

[QUOTE=hoosier xlc;1094991]Hrdly, damn fine job on the tank mount, you gonna leave it brushed alum look?

Yeah, sort of...I just hit it with a little Semi-Chrome polish when I installed it...Here's a pic when I first installed it along with the starter cover plate and S&S Carb bracket I made. That was a few years ago. Their still on and holding up.

Point for anyone reading this is you can make some of your own parts...however small they are...and really put some one-off items on your scoot to separate yourself from everyone else out there.

Your pump cover is A-1 workmanship. Ever think of starting your own cottage industry for H-D custom parts. Only need a couple of items to get started. Sell em' on E'bay for starters. There's always room for quality 'American Made' parts. :smoke

[hoosier xlc]

Hrdly,
I am actually testing the waters with this, I haven't seen a custom pump cover unless it was on a custom pump! I think it's bull that a guy has to toss down $400 plus for a custom pump when the bodies are the same, only with a different face cover. The stock bodies are more than adequate to oil these bikes and look great when polished up, now if a guy could just buy a custom face cover to dress up his pump for alot less coin, that would probably sound more appealing than changing the whole pump.

Alright now that that's out of the way.

This is a fantastic pic! I am diggin the holes in the fins on the head, more air evenly distributed and lighter weight, awesome stuff Hrdly!
http://www.xlforum.net/vbportal/forums/attachment.php?attachmentid=14029&d=1202529584

[Mohntonite]

And you're not making these for the masses , because??????????

[HrdlyDangrs]

You know, the best way to get started with little to no money is to make up the one or two parts that you want on your bike. Install them and rack up some time and miles (your R&D Testing) while letting the bike be seen at as many area bike hang-outs as possible.

Bet it won't take but one or two stops before a friend or two spots your one off items and wants you to machine one for his bike. After that....Hey who knows...:smoke Hrdly

Hey hoosier, tomorrow I'll post a pic of my aluminum front motor mounts with the holes. I haven't install them yet, but theyre way cool. :smoke Hrdly

[hoosier xlc]

Right on man, send me a PM with a link so I won't miss em.

I have a couple more ideas for a few other items that i'm currently working on drawing up. I will post them also when I get them made up.

[HrdlyDangrs]

OK, tomorrow then. Have to get them out of my tool box in the shop and snap a pic. Later, Hrdly :smoke

[hoosier xlc]

Thanks for all the compliments everybody!

Anybody notice the cover kinda resembles the Hoosier state?:)

[hoosier xlc]

Alright last set of pics until it's on the bike.

Got the polishing done today, only took an hour or less.

Started off wet sanding this morning, going from 800-1,000-2,000, nice even stroke as to not gouge, the ball milled slots were kind of a pain to get all the way into, but all in all not to bad.
http://www.bikershangout.com/gallery/data/500/medium/polishing_cover011.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover013.jpg

After the wet sanding I started the polishing..do not have any pics of the polishing, sorry not taking my camera out there and gettin it filthy. Anyway here's the finished product, now all I have to do is wait for the NPS pipe tap to come in to tap the oil passage holes, then mount it on the bike.

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover002.jpg
That black at the top is the reflection of the towell against the table.

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover003.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover004.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover007.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover006.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover008.jpg

http://www.bikershangout.com/gallery/data/500/medium/polishing_cover009.jpg

One last question...If this was avaliable for a fair price, would you put this on your Big Twin?

[Sportster1200]

Alright last set of pics until it's on the bike.


One last question...If this was avaliable for a fair price, would you put this on your Big Twin?

I think it would have to be chromed and some LEDs that flash off and on to work on a Big Twin OR could you make it in a Skull shape?

Just kidding. I think it looks good. The biggest problem is most people won't buy parts like that unless they are very visible but there could be a niche market for them. Figure out a cost and get it covered in one of the new product sections in the popular bike magazines.

KongBastard

[loki03xlh]

great job on your custom part. I wish I had the skill and tools to do the same. If you offered parts like this for my bike, I would be interested.

[hoosier xlc]

The biggest problem is most people won't buy parts like that unless they are very visible.

KongBastard

The Oil Pump on BT's from 66-98 are highly visible on the side of the crankcase. Mostly overlooked because they are so plain.

About that skull comment for the BT's....I think Chuck had a Wal-Mart Skull on his "Sissy Bar" on the Sportster if i'm not mistaken.:laugh

[hoosier xlc]

Thinking about making wideglede triple trees for the 39mm front end next!

Will post another thread when I do.

[HrdlyDangrs]

Hoosier....The cover looks great!..As fine a custom part as any out there. Now the real test comes...installing it and seeing how it works.

Here's a pic of my 74 XLCH's front aluminum motor mounts. Needless to say I haven't installed them yet but eventually I'll get around to it when I set the 74' up as a 'Period Correct' Drag Bike. I have more parts to make including a set of 'rear-sets' for shifting/braking as well as some other light weight aluminum parts.

You could probably knock flat items like these out in no time. I also have other ideas and drawings that I've been working on for light weight aluminum racing parts for the XL's. Some of which when completed will go onto my 74 once I get around to setting it up. :smoke Hrdly

[theoldog]

Fantastic work, great job! Have been making quite a few parts myself this winter-not much turns out that nice though!!

[rickxx]

great work guys!

[hoosier xlc]

Hrdy,
Man those look sweet great job! No doubt the cover will work, it is an exact duplicate of the original with a different look, now if I changed it to flow more then I would worry about the operation. Flat parts like those brackets for example can be done in the CNC in about 30 min for both start to finish. I have access to 3 CNC's, but prefer to make parts manually in the Knee Mill or in the Clausing. Keep up the good work!

Steve,
I figured you would be making a few new bits this winter, I have seen your parts...second to none!

[hoosier xlc]

WideGlide conversion will be the next project, if you all enjoyed this thread I can do another on the WG conversion when I get around to doing it.

My front end is off of an 1997 Sportster, so the WG conv would work on a few bikes here.

[johnnysquire]

Hoosier -

Are you going to clearcoat the aluminum to keep it shiny?

[hoosier xlc]

Hoosier -

Are you going to clearcoat the aluminum to keep it shiny?

I strongly considered it, if I can find a clear that will hold up and not yellow.

[hoosier xlc]

Well I got the cover finished up and installed today along with a 30 min run at varying speeds., everything went and worked great! No ticks, no knocks, pressure light went out as normal, no leaks, flow and return work as they should. I guess you can officially say it is a custom part. Here's a couple pics of the finished/installed product.
http://www.bikershangout.com/gallery/data/500/medium/cover_install002.jpg

http://www.bikershangout.com/gallery/data/500/medium/cover_install005.jpg

Hope you all enjoyed the thread and pics.

[Rascal]

Ever get the urge to just make something from nothing?

This is how I spent my Thursday evening. For all who doesn't know, it's an Oil Pump Front Cover from a Big Twin, couldn't find a custom cover for my oil pump....so I made my own!

Here's a shot of the original Pump Cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover010.jpg

It's gonna start with the T6061 Aluminum that I had already face milled and drilled a couple holes in before I got around to start snappin pics.

The Aluminum with the cross holes and a face cut.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover011.jpg

Mounting holes being drilled.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover013.jpg

Oil Cavities being milled.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover017.jpg

Oil Cavities in.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover019.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover021.jpg

Set up to drill Feed and Return Passages, these will drill into the cross holes in the face.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover022.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover025.jpg

Alright now that all the Oil Passages and Mounting Holes are in we will start profiling the Pump Cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover026.jpg

Putting in a few Radius cuts.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover027.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover028.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover030.jpg

The Profiling continues.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover031.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover032.jpg

Starting to become somewhat recognizable.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover034.jpg

Add a few Ball Mill Accents and give myself a reference line to finish the profiling.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover038.jpg

The rest of the profiling was done by cutting the excess off in the bandsaw and finishing the Radius' with the belt sander.

The Cover is still rough as I need to wet sand and Polish it yet.

Here's a shot of the new cover compared to the old cover.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover001.jpg

Gasket fits properly.
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover008.jpg

Side shot
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover002.jpg

Another comparison
http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover006.jpg

Let's remember this is still rough, it needs wet sanded and polished before it is done. I will start the polishing process this weekend and toss you all a few final finished pics, just wanted you to see the process so far.

Here's a few more pics for ya.

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover005.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover004.jpg

http://www.bikershangout.com/gallery/data/500/medium/Pump_Cover007.jpg

That's all the pics I have until the Cover is Polished and finished.
Hope all of you enjoyed the pics and process.

Great job! Thanks for the awesome pics!

[hoosier xlc]

Thanks for the compliment Rascal.

[hoosier xlc]

It's still workin great after almost a year and a few thousand miles.:clap

[dre986]

A man of talent. Very nice job.

[prettyponyofdoom]

Just now saw this post - amazing talent and awesome looking piece.
Thx for the DIY picture post and update.

Happy New Year to ya!

[sporty01]

nice work hoosier i wish i had machining skills i only know how to run and program a wire edm. but i was able to do the jugs on my old 900 xlch with the wire edm they came out nice and only had minimal honing to finish them up by the way from what part of indiana are you?

[hoosier xlc]

A man of talent. Very nice job.
Wow, and to think someone on here once said I had no talent, hold on I think it was no skill.:doh Thanks 986.

Just now saw this post - amazing talent and awesome looking piece.
Thx for the DIY picture post and update.

Happy New Year to ya!

Heya PPOD thanks and Happy New Year to ya, hope it's filled with happiness for ya.

nice work hoosier i wish i had machining skills i only know how to run and program a wire edm. but i was able to do the jugs on my old 900 xlch with the wire edm they came out nice and only had minimal honing to finish them up by the way from what part of indiana are you?

Good Job 01, EDM is an awesome piece of machinery that takes a good deal of skill to operate. North Central part of IN here, between Indy and the Fort.

Anyone on here can do thier own parts and i'll tell you all exactly what I tell my sons, "The only thing that keeps a person from excelling at something is thier fear of failing at it".:)