Well, it was kinda my idea to have a Project thread page. I mentioned it anyway. Since I have a new project, I guess I had better post something. I appreciate all the trouble Gary and Bert went to. On to the project.

In 1999, I saw my first Buell S1W while on vacation with my family in Ohio. The next day, on our way home from vacation, I stopped at a Harley-Davidson/Buell dealership and checked one out. Wow, I thought it was the coolest bike I had ever seen. This was on a Sunday. The next morning, I started calling around and found a brand new 1998 Buell S1W 'Black Lightning' in Charleston, WV. The dealer's son was keeping it for himself but they agreed to sell it to me. I made the deal and took possession the next Thursday morning. I had been out of motorcycling for about 5 years. My family was young and I didn't have the time to ride. The Buell got me back into it. I come from a riding family. My Dad was a Harley rider since the 1950's and both my maternal and paternal grandfathers rode bikes. My maternal grandfather was a hillclimb racer. I got my first bike when I was 7 years old.

Anyway, I rode the S1W a few years but only put 7300 miles on it. The big problem was that I live on a farm located 1 mile up a gravel road. The Buell was getting beat to death on the gravel road. Soon after buying it though, I had some health problems and the bike just sat. Heart surgery slowed me down for a year or 2. I purchase a Yamaha Zuma scooter in 2003 and starting riding again from time to time. Then in 2004, I bought an '04 KTM 625 SMC 'Supermoto' bike. This bike got me back into riding everyday again and I decided I needed a touring bike. I purchased a 1995 Buell S2 Thunderbolt. Great bike but it seemed a little to heavy and it wasn't very fast, so I decided to sell it. Stay with me this is germain to the story. The S2 wasn't worth much, so I parted it out on ebay and made a killing on it. At this time I became aware that KTM was producing a new 950 streetbike. I decide to get one. The KTM Supermoto had increased in value since I bought it and I sold it at a profit this past spring and purchased the 2005.5 KTM 950 Adventure S that is now my daily driver in June.

In early spring of 2005, when I was riding the SMC daily, I found a phone number on the internet for C&J Racing Frames. I called Bill the new owner of C&J and we talked a few minutes about the Street Tracker frame that they were currently building. I told Bill that I had a 1998 Buell S1W sitting in my shop and that I might be interested in a frame. He said that it was my lucky day, as they had a Buell in the shop and they were mocking up a frame for it. Now was the time to act! I had just purchased a complete NRHS Stage 3 XL1200R topend and Red Shift .585" cams. I was the first person to buy the new just on the market Axtell Nikasil 1250 cylinders. Previously, I had put a NRHS Stage 3 Thunderstorm kit on the bike and made great horsepower out of it. Years before when Brian Nallin was still at NRHS I had talked with him about building a Street Tracker. I decided that it was too expensive as they were charging BIG money for these bikes but it was always in the back of my mind. The thoughts of getting a Street Tracker all came rushing back to me. I sent Bill at C&J a $500 deposit that same day for my new frame.

The reason I had decided to go the Street Tracker route with the Buell, was because I need a bike that I can take to the Harley rallies and to just cruise on. The Buell was a great bike but it didn't fit in quite right for my use. I really wanted a Sportster. I tried to buy one from my local dealer but they think their Sportsters are made of gold or something. They would not sell me one for MSRP. Out of this the ST was born. To me the XR750 racebikes and the XR1000 streetbikes of the mid 80's were the hottest Sportsters ever built. I love the old XR bikes. My bike promises to be just as much fun as those old bikes but l wanted it to have a more modern engine in the XR style. At first, I considered 4-valve heads from Maximum Torque Engines. I am a dealer for those heads but they require custom exhausts because the ports are at 90 degrees to the bike, meaning they are facing forward and backward. I knew that I definitely had to have dual carbs on the bike. No matter what it had to have dual carbs. At about this same time I realized that Brian Nallin was working at Revolution Performance. They had just put a new XR style STD head kit on the market with all the parts I would need to bolt it onto my new Street Tracker engine. OK, now I'm sitting on a new NRHS 1250 kit that needs a new home. I put that kit up for sale and sold it within a week to a guy in England. That was the greenlight I needed for the Revolution kit. I called Brian and we struck up a deal. Brian remembered that when I bought my first Stage 3 kit from him, I also gave him a $100 deposit on the first dual carb kit he was considering building for the Buell motorcycles. He had left NRHS and the dual carb kit never happened. I just figured I was out the money and I wasn't very worried about it. He made that MORE than right with me and I had a short wait for my XR kit from Revolution. Brian and Revolution built the custom 90" engine for the Confederate Wraith. The Wraith uses XR style heads. Mert Lawwill of dirt track racing fame also builds a Street Tracker bike. His bike costs $29,000 and only comes in one color. It's built on the new rubber mounted Sportster frame but I don't like it as much as I do the C&J frame.

My frame arrived 8 weeks after I ordered it, just like Bill had promised. I sent a few parts out to C&J and because of this, I had no real mockup to do on the rear suspension and axle parts. Everything including the brakes bolted right on. My Buell trees and S2 Roma forks also bolted right up to the new C&J frame. New bearings were included to make everything a simple bolt on job. I purchased a new Penske rear shock from C&J and they also sourced the Race Tech aluminum fuel tank for me. Race Tech builds fuel tanks for Storz. A few years ago I was fortunate enough to find an ULTRA rare Buell Racing/Performance Machine 6-piston leftside Buell caliper (1 of 9 in the world). The bike will have triple German made Braking USA wave rotors also. The rear caliper is a 4-piston PM caliper for a Buell. Marchesini wheels from an S2 and Dunlop 208 tires will be used. To make the project more cost effective, as many stock Buell parts as can be, need to be used on the bike. So a lot of the parts are from the original Buell S1W.

That's it in a nutshell. I'll post a picture of the bare frame and swingarm along with a picture of what I have done to date. The frame has the oil tank located in the backbone under the fuel tank mounting location. It does not use a dipstick to measure the level. Basically, if you can see oil in the tank it's good to go. The bike will also have external oil lines w/braided hoses, a Storz tailsection, Corbin seat, Motion Pro single pull throttle housing, dual Mikuni HSR45 carbs, a SuperTrapp dual leftside exhaust, Storz Sportster rearset footpeg mounts, Storz shifter and brake lever. I still have a few parts to get but not much. All of the engine parts are here. Back when I rode the Buell S1W, I bought a ThunderHeart Buell billet ignition. The ignition failed during a dyno run on my bike. ThunderHeart replaced the module and the new one will be used on the ST. It is completely adjustable with dual rev limits, offset rear cylinder mapping and all the bells and whistles. I can hook my laptop up to it and make changes during a dynorun. Very Trick. I have spared no expense on this bike but believe it or not, I don't have very much money in it. The C&J frame with the swingarm, oil tank and all the engine mounts weighs 100# less than the Buell frame with the same parts. Because of this the bike will weigh around 300# when completed. That's what we are shooting for anyway 300#. The XR style Buell engine will putout around 110rwhp. In a 300# bike that is all it will need. Anything more and the bike might become dangerous on the street.

Please post your comments and check back often. The bike is sort of at a stand still right now. The tank graphics should be done this week. They are patterned after the new 2005 XL883R tank stickers. Mine will have HARLEY-DAVIDSON XR1250R printed on them and will have a Buell blue stripe instead of the Harley orange stripe. The bottom picture shows the new STD heads.

S Won
http://swon.zoto.com/img/45/88021d15eaa63d796356217ff94607ee-.jpg http://swon.zoto.com/img/45/76b5adc1cf95063894334882ecf4a2ee-.jpg http://swon.zoto.com/img/45/5d33e6460134fb1b8bdafb37995880e6-.jpg

I'm working on a street tracker conversion myself. I have my 1989 Sporty and I'm working with Chris Leger from Track-Tek. I have the parts ordered for all the cosmetic changes. I did motor work several years ago so my bike has been ready for a facelift for quite some time. :) I'm sticking with the stock single carb set up but you'll certainly have the true look of an XR with the dual carb set up. I got lucky and found an 18" cast rear wheel from a 79 sportster so I'll be swapping out the 16" wheel for the 18" wheel and adding 15" shocks in the back too. Lots of other goodies to change and add. I'll update as I go. Good luck and keep sending pics. :) regards, chieftd

cannot wait to see the finished product!!!!

Man, about all I can formulate past the tears in my eyes is...WOW..that is going to be a one of a kind cement shredder!

man I'd luuuurv to live stateside......you guys have got soo much stuff on ya doorstep and CHEAP...


STD heads ......mmmmmmmmmmmmmmmmmmm with my 88" :D

I would have heaps more toys than I have now

hey stevo do you have a link for that frame company? I am interested in that frame I have been lookign at the spondon frame but am kinda interested in this one and was wondering if they made a more street sport bike style frame for the sportster motor.

Great project you've got going! I LOVE THAT FUEL TANK! Keep us posted.

Sounds like a cool project, look forward to more pics :D That thing is gonna scoot :banana

Good on you!! Had a 1984 XR-1000 myself. Slate Grey. Still have the original touch up paint. Bought it in VA, shipped it to San Dawg, and a few years later rode it from San Dawg to GA, and after 5 years let it go when the young'ns started arriving, miss it lots. Still looking for a set of pipes with the unique sound like the XR's stock exhaust. Haven't heard any exhaust like it since. It was a somewhat muffled beefy sound, but deep as hell, kinda like a sporty boxer beemer on steroids. Not that clackity stuff coming out of today's after market mufflers. It ran best in the desert heat going 65-70 when the limit was 55. The noise wasn't noticeable while riding either, but everyone always stared at it. Good luck, you'll get plenty of attention with the style.

Thanks for replying to my thread everyone. Quiet One, I especially appreciate input from the XR guys. Thanks! One of the reasons I am building this bike is because I loved the old XR bikes so much. I always wanted one but could never get that to come together. This bike is going to fix that for me. I have entertained the idea of selling it after I complete it but I'm not sure that's going to be an option for me. I love looking at the bike right now, and it's not even close to being done. Riding it is going to be awesome. I have other bikes but this one is going to be my favorite. It won't be my daily driver or anything like that but for summer cruising, it won't have an equal. My wife rarely rides with me anymore. She is concerned about something happened to both of us at the same time. For the kids it's a valid concern. We have plans for riding a lot when I retire in about 12 years. Anyway, since she doesn't ride with me, this bike doesn't need to have passenger pegs or a pillion.

I really don't have any updates to post other than yesterday, I removed the front numberplate and the front fender. I think in keeping with the spirit of this bike the fender is not needed. The numberplate was in homage to the XR racing hertiage but since this bike is a streetbike and not really an XR. I ditched it. This is an ongoing process so I can't say they won't go back on at sometime but for now they gone. I'll try to take some pictures tomorrow and post them. The picture below is an earlier picture, I took after I installed the trees and the S1W forks. It shows what the bike now looks like with the exception of the handlebars and dash panel. The S2 forks that are now on the bike raised the front a few inches from want it was in the picture.

I hope to start putting the engine together soon. Maybe tomorrow if I get a chance. I'm coming off nightshift and it's 4am now, so that isn't looking good. I'd like to set the engine with the cylinders and heads bolted on, into the frame so the exhaust system mounts could be mocked up. If I get it in I'll post a few more pictures.

S Won
http://swon.zoto.com/img/45/857e41f1141defd7e489d2b9d0a23b64-.jpg

Well I owned a 66 xlr and ran on drag strip. I built several kr into khrs for the street in 66 /67 and ran my xlr on the street no gen just mag in front. had small light batt. to get by on street for brake light.they were a fast bike. never ran a xr750. later ones. All my were kr but for the xlr. looks good am building a 85 motor with the xlr specks. cu gar

Nice seeing you on this forum, S won!

I've said it before, and I'll say it again. Wow. Maybe an 88" motor would be too much in a package that light. And you better not use more than 2 fingers on those front brakes...

That looks just like my "fantasy" Sportster, except mine has clip-ons, rearsets, and a "toaster" tank. Please do the entire motorcycling world a favor and take that thing to some track days. Hopefully those "sport" bikes won't get in your way too much...:tour

Loos like it's going to be one Helluva Bike!!!:D

Yesterday, I stripped the frame down and my brother helped me install the engine into it. The Buell engine bolted in without too much trouble. Actually, we laid the engine down flat and then dropped the frame over it and bolted in the engine brackets. I picked up some bolts today to use in the base plate located behind the transmission. The C&J frame eliminates the heavy swingarm bracket that the Buell needs to bolt the swingarm to the engine and frame isolators.

AZbiker,
Thanks again for turning me onto this site. I've really enjoyed posting about the bike on this site, more than the other sites I belong to. These guys are Sportster guys and they appreciate bikes like this more than other riders. Yes, the 88" engine would be too much for it. As for the Buell Racing dual calipers, you have to remember that the bike also uses a bigger mastercylinder. That mastercylinder pushes more fluid with less pressure, so it won't be as big an issue as you think! Also, my Super XR will use rearset engine mounted footpeg brackets from Storz.

I don't have any pictures of the frame/engine combo bolted together yet. There really isn't much to see anyway. In the next few days, I'll post a picture of what it looks like. The next step is to bolt the forks, rear suspension, wheels and brakes back onto the bike along with some engine parts. The cylinders, heads, and exhaust will be bolted on, so that the exhaust brackets can be mocked up. The top and front engine brakets will also need to be drilled and bolted in.

Stay tuned!

S Won

That’s going to be one of the coolest bikes ever! From the image above it looks like your building it in your house, as it should be. Can’t wait to see more.

Sorry, guys! I've been busy with work and deer season and haven't touched the bike in over a week. If I get around to it I'll try to get that picture of the frame and bare engine posted.

edman, the bike is being built in my shop. Years ago my brother started building a house on our family farm. He and his wife at the time abandoned the house and I turned it into my motorcycle shop. It works for now but it's only 24' X 16' so there isn't much room. Besides I own other streetbikes and dirtbike that are shoved all different direction in there. I also have building supplies stored in there. Space is at a premium.

S Won

Wow, I just checked this site and I can't wait to see more pictures. How much was the frame?

wolfgang,
The frame is from C&J Racing Frames in San Marcos, CA. They don't have a website. The frame cost me $2400. It was worth every penny. It's truely a work of art. The frame is made of chromoly tubing and the TIG welds are beautiful.

S Won

How do you post a new message on the forum? I don't see any headings on the subject.

Another small update. I can't believe the bike is turning out as nice as it is! We installed the bare engine a few weeks ago. Today, I had some time, so I started putting everything back together. I think, I'm starting to like the fenderless look better and better. This weekend will be the next time I'll be able to get back into the shop. The pictures didn't turn out as good as I thought, because of the clutter behind the bike. The engine isn't finished, it's just mocked up. The pistons and rings are not installed and the head bolts are just finger tight. Today, I bought an engine stand for the work that will eventually need to be done. Now I can bolt the engine down to the bench. The whole bike will need to come apart again for paint and plating. I'm considering sending the WP inverts to Factory Connection for a revalve and to have them black anodized. I might have the frontend lraised at least an inch. The exhaust is next in line for mockup this weekend.

I hope you guys like the pictures! This thing is going to be awesome. I can't wait! What do you think?

S Won

http://swon.zoto.com/img/45/b3977edce09ee2243e94e9c87a95a5dc.jpg

http://swon.zoto.com/img/45/56508b73f3f53eaf33923979d1d5eee0-.jpg

I would like to see a comparison of frame weights. WOW, that is going to be sweet!

The new C&J Racing frame weighs only 40lbs. This 40lbs includes the frame, swingarm, integral oil tank in the frame and all the engine mounts. Since this bike is built using a Buell donor bike, the C&J frame replaces the stock Buell frame. The C&J frame is a much simpler design and overall it will make a better bike. The Buell S1W frame with all the same pieces is much heavier, it uses more parts and is much more complex. The Buell used a uniplanar engine dampner system to dampen the engine vibrations. Also, to bolt the swingarm and engine together Buell used a heavy cast swingarm mounting plate. So, with a separate oil tank, a much heavier steel swingram, the required mounting plate, isolators, engine mounts and heim joints, the stock Buell frame weighs very close to 140lbs. I know that sounds like a lot but it's true. I have no idea what a stock Sportster frame weighs but it isn't even close 40lbs. I would imagine that a Sportster frame weighs as much or more than the Buell frame does.

This bike is going to be very cool. It's all engine. I want to get the rear axle parts and wheel on this weekend, and hopefully get the exhaust bolted on. Next the engine mounts will need to be bolted on and the holes drilled so they can be bolted on. A steel bracket will be fabbed and welded onto the frame below the neck. This will be the coil mount. It will be located just below the front of the oil tank. This engine uses VERY trick STD XR style heads with external oil lines. Thes will be plumbed up with braided steel oil lines. The lines running to the oil tank from the oil pump will be the same. The bike will have Buell XB head breathers and dual filters under the Harley XR750 tailsection.

I am very please with the look of the bike and how it's all coming together!

S Won

http://swon.zoto.com/img/45/b3977edce09ee2243e94e9c87a95a5dc.jpg

Looking Good S Won!!!!!:clap :clap :clap :clap

S Won - I like the front and rear frame stands! Who makes them.

A stock sportster frame and connected swingarm weighs 60 lbs.
I am converting mine to rigid(tacked together right now), current weight is 49 lbs before welding and gussetting. I still need to add an oil tank. My engine mounts and bolts will also add a few lbs.
MattD

thats an awesome project! fantastic job

Also, how light is that tank, and how much fuel does it hold?
In case I forgot to mention, I do think it is an awesome project also.

MattD

The top picture shows the Racetech fuel tank. The aluminum tank weighs just a few pounds. I have never weighed it, so I don't have an actual number. It's very light though. Racetech hand fabricates all of Storz fuel tanks. I believe it holds 3.5 gals. The lifts are from Handy. Both of them together cost me $99. Worth every penny! I have used them on all my bikes.

The second picture shows the stainless steel all-thread mounting stud for the fuel tank. This is the same way the XR tank is mounted on the racebikes. The in-frame oil tank can be seen in that photo also.

Today, my wife picked up the threaded insert that I need to align the engine in the frame. This weekend that will be done. I'd also like to get the rear axle, wheel and brake parts back on along with the dual SuperTrapp exhaust pipes. Next the motor mounts will be bolted on and drilled for mounting. I will need to weld a bracket on the frame for the coil. A plate will need to be mounted behind the engine for the stator and circuit breakers. The battery mounts up under the tailsection.

This bike uses many speciality parts. I'll not try to list them all here but a couple of them are the STD heads and the Red Shift XR cams. The heads are actually 2 front heads with the ports moved from the right side to the left. They also feature raised oval intake ports. Red shift takes standard type Sportster cams and machines off the lobes. They then weld need new higher lift lobes back on. The difference with these are that the lobes are reversed on the rear cylinder because it uses a front cyinder head. Very trick!

Thanks for the kind words everyone. I'm very excited about the bike!

S Won

http://swon.zoto.com/img/45/95d9f23c52dced5bacf5b1f950ee76ca-.jpg
http://swon.zoto.com/img/45/afc09db094a18000cb04d78790c83a55-.jpg
http://swon.zoto.com/img/45/71699faae434fa11c70028e02044d5be-.jpg

I wanna hear it run! I'll bet its gonna fly

We're shooting for 110rwhp. Yes, it will definitely fly!

I haven't mentioned this before and I hope nobody takes this the wrong way! The bike is being built because my local dealer would not sell me an XL883L at MSRP this past year. They wanted $8100 for a bike with a $6495 pricetag. It made me so mad I switched brands and bought a new $13,000 2005 KTM 950 Adventure S. I knew that I would also needed a Sportster, because I love the air-cooled V-twin quad cam engine. So, I decided to build one better than Harley could make, using my Buell S1W as a donor bike. I'll never buy another bike from Harley-Davidson or Buell.

I don't want to turn this thread into a Harley slamfest or anything like that. I just have a really bad dealer that has done me wrong so many times, that I can stand it anymore. From bad techs doing terrible work on my bikes and overpriced parts, to being ignored by the salemen and too high price quotes. I simply had enough!

Sorry for the rant!

S Won

Hey S WON,
Are you going with a rear twin shock set up or Mono system? kind of tough to tell but looking at that nice fabbed swing arm I take it you're using two?
Very nice project, can't wait for the end result.
Swankster
I guess I found my answer as I just viewed your initial pics. A single set-up it is ha?
Hope it performs well for you...
Rich aka Swankster

Just caught up with this thread and I will certainly be following your progress. Can't wait to see the finished bike.

now this is they way to use a buell doner bike!!!! i can't wait to see it completed... when do you plan on finishing the bike?

i know that this is not supposed to be a "bash hd" thread...but i agree that many dealers are rediculous. i have been window shopping for sporsters since the rubber mounts first came out. the msrp dealers happened to also only have bikes in stock that had a bunch of accesories already bolted on. the non msrp dealers would match prices at certain times of the year. another dealer could have cared less that i wanted to buy an 883 sportster, i guess the commision was not enough.

in the end, i found the bike i should have gotten 2 years ago, an 02 883r at a used dealer in manchester nh. i got a great trade in value for my sport bike compared to what the hd dealer offered, and was more than happy with what i paid. i was much happier without dealing with all of the hd b.s. and hiddden costs. i don't want to d=get started with the horrible customer service at the boston hd parts counter

We're shooting for 110rwhp. Yes, it will definitely fly!

I haven't mentioned this before and I hope nobody takes this the wrong way! The bike is being built because my local dealer would not sell me an XL883L at MSRP this past year. They wanted $8100 for a bike with a $6495 pricetag. It made me so mad I switched brands and bought a new $13,000 2005 KTM 950 Adventure S. I knew that I would also needed a Sportster, because I love the air-cooled V-twin quad cam engine. So, I decided to build one better than Harley could make, using my Buell S1W as a donor bike. I'll never buy another bike from Harley-Davidson or Buell.

I don't want to turn this thread into a Harley slamfest or anything like that. I just have a really bad dealer that has done me wrong so many times, that I can stand it anymore. From bad techs doing terrible work on my bikes and overpriced parts, to being ignored by the salemen and too high price quotes. I simply had enough!

Sorry for the rant!

S Won

If I added up all the dealers in Arizona that would sell an XL883L for $8100 I'd have a big zero. I bought my 883 standard from the lowest priced Az dealer for $8250. Thems the breaks if you don't want to pay air fare and shipping/riding from some location across the country just to spite all the state dealers.

I guess the connection isn't too clear on jumping to an "adventure bike" from a low rider. Did you intend to strip the new 883 low from the start to make an adventure bike? If so, the Buell Ulysses should be the same money as the KTM or less and be air cooled with quad cams.

Then again, if money is no object, why jump ship on brands?

:dunno

PS - It does look like it's going to be a nice ride.

We're shooting for 110rwhp. Yes, it will definitely fly!

I haven't mentioned this before and I hope nobody takes this the wrong way! The bike is being built because my local dealer would not sell me an XL883L at MSRP this past year. They wanted $8100 for a bike with a $6495 pricetag. It made me so mad I switched brands and bought a new $13,000 2005 KTM 950 Adventure S. I knew that I would also needed a Sportster, because I love the air-cooled V-twin quad cam engine. So, I decided to build one better than Harley could make, using my Buell S1W as a donor bike. I'll never buy another bike from Harley-Davidson or Buell.

I don't want to turn this thread into a Harley slamfest or anything like that. I just have a really bad dealer that has done me wrong so many times, that I can stand it anymore. From bad techs doing terrible work on my bikes and overpriced parts, to being ignored by the salemen and too high price quotes. I simply had enough!

Sorry for the rant!

S Won

no reason to be sorry for the rant, I think we have all had our run ins with bunk dealers. thats a sad but true fact.
You are on the right path for sure, if you want something done right, ...well, you know how it goes.:banana

this ~~~>:tour will be you soon enough

Well, the reason I jumped brands was because I couldn't stomach the markup. The KTM is a much more advanced motorcycle. I ride dirtbikes and live on a very rural gravel road. The Harleys were always trailered in and out. The gravel just tore them up too badly. It was time for a change for the better. Besides, I don't pay MSRP. I never have and I never will. It wasn't the money, it was the principle of it. I know the value of a dollar. The 883L simply wasn't worth $8100. If that's what it takes to do business with them, I'm done! I was willing to pay MSRP to get the 883. I'd been looking at the Adventure bikes for awhile. It was a good change for me. The XB12X was not released until after I bought my 950 S. The XB12X is really a streetbike not an Adventure bike and the name is plain stupid. My KTM cost me $13,200 out the door w/bags. Way less than MSRP. You'd never get a Harley dealer to sell you an XB12X for that! Some people are loyal to the Harley brand to no end. I'm not one of them! I've seen more people screwed over by the Motor Company, than I care to admit.

Back to the project. We had our first major setback today. The custom Supertrapp dual exhaust DOES NOT fit. The front pipe hits the left downtube and the rear pipe hits the rear shock. I'd say that's pretty major. I'll contact Revolution Performance on Monday and try to sort it out. I'm also going to call Supertrapp and make sure the proper exhaust is available. Building a bike that nobody has ever built before sure isn't easy. If we can't get the Supertrapp exhaust worked out, I'm going to be very tempted to start selling off parts! One option might be to take the bike to an exhaust shop and have the pipes bent to the proper specs. That could probably done pretty easily.

Stay tuned!

S Won

Bend your own system or buy bends and weld it up...

I'm gonna be doin a similar thing when mine goes back together as there is a LOT of HP to be made or lost in the exhaust....

Bending up a system isn't really something that I want to get into. I purchased these parts and I was told that they would all work together. I'm not interested in using the STD XR heads without the SuperTrapp exhaust. I'm also not interested in building the bike without the XR heads. Putting standard type heads and a conventional exhaust would solve my problem but it's not what I want. I could have just bought a used Sportster if I wanted a bike like that. My best option is to see if C&J Racing can fix the frame with a center mounted shock.

S Won

Happy New Year everyone! I thought I may as well post a quick update of the project, since I was up tonight. I'm working! After the major problem with the rear shock, I have decided to cut the frame up and redesign the rear suspension myself. I have a buyer for my rear Penske shock and now, I'm looking for a cheap WP Racing PDS shock, fat chance! The WP will cost me $1426 retail but I'll only pay $1212 after my discount. The shock mounts are currently being removed from the frame. This is actually a plus as it will remove some weight from frame. Not much but a little. The truss has already been cut off the swingarm. Removing these mounts will allow the SuperTrapp exhaust to work on the bike. The shock will be mounted in front of the rear tire and should work ok in that location.

I hope to get pictures of it posted soon but, I'm redoing my shop. Santa brought me some new shelves and a stand for my Buell engine. I must have been a good boy! Yeah right!

S Won

S Won,

Glad to see you're continuing with the project. It's going to be one awesome bike.

Hi S Won, Can't wait to see that bike together. I have a 99 Buell S3T that I have been considering doing something similar. Was the C&J frame built in relation to your body size?
And can I take your KTM for a ride? I'm looking at one of those too.
Cactus Jack

Ok is it me or is this the cleanest shop/bike work area ever?!!!!! If i were doing this the pics would show about 5 broken screwdrivers and wrench or two twisted, and 50 beer bottles, and oh yeah half the parts on the floor.



(hey how'd i end up with all these extra screws and nut, ah i dont need them...)

GREAT PROJECT BTW!@!

Thanks everyone! First things first. The frame is a custom Street Tracker frame that is just basically a dirttrack style frame that has been changed to work on the street. It wasn't built to my body size per say, but it was changed from the regular dirttrack style. I'm 5' 10" and weigh just over 200lbs. I have a bit of a gut on me. I'm currently trying to lose that! The wheelbase is 56" long and the rake is 26.5 degrees. They built these for strength. They are made of chromoly and are very stiff. That is where some of the problems started. The frame was somewhat built to my specs. I sent my rear wheel components to California for the mockup in C&J's shop. All of the rear components basically just bolted in when I got the parts back. This saved me considerable time. The Buell fork clamps also bolted right onto the C&J steering neck. C&J supplied the correct steering head bearings. I had to source 2 stainless steel washers to use as spacers. These spacers were needed to keep the seals on the bearings from tearing. The front downtubes on the new frame are angled outward, for strength as they go down. This caused the first problem. The left downtube doesn't give enough room for the front SuperTrapp pipe to exit the front STD XR head. The second problem was that the side mounted Penske shock di not allow enough room for the SuperTrapp exhaust to correctly bolt onto the frame. As I have posted earlier in the thread. The side mounted frame brackets are currently being cut off the frame. This is rather touchy work and is going to take a little time. I'm trying really hard not to ruin anything. The rear support tubes for the tailsection are asymmetrical because of the side mounted shock. Those brackets are being cut off and replaced one at a time. Hopefully, this will keep everything from moving around. Cutting these off will also give me more room for the conventionally mounted shock that I will be adding. All of the new parts that I will be making and installing, will just be tacked into place. The frame will be taken to a local machine shop where everything will be TIG welded back into place for strength. They do good work and I trust them.

I have just purchased 2 Buell XB12 rear shocks off ebay. They were cheap enough that I was able to get 2 of them for just over $120 including shipping. It's nice to have a spare. The Buell shock is smaller that the Penske and should fit inside the frame better. I paid $720 for the Penske. It's funny, one of my first questions to C&J was the use of such a high priced shock. I didn't want to spend that much, as cheap shock replacement was something that I wanted. Buell parts are cheap! Anyway, I think this is correct course of action to fix the short comings of the side mounted shock. The only problem I can see now, is the rigidity of the swingarm. The truss has been removed so the swingarm isn't as rigid as it was before, with the truss. I might need to make a new truss for the swingarm. This should be no problem.

Thanks for the comments about my shop. It's a small 24' x16' building that my brother framed up a few years ago. It was to be the kitchen and living room of his house. He moved away and abandoned it soon after starting it. I live on a small family farm. The shop is located just down the road from my house across from my mother's house. My wife and I are getting ready to build a new house. We currently live in a remodeled barn, that my father and I built in 1976. This house will eventually be my new garage and motorcycle shop. My shop is sort of cluttered right now but this weekend I'll be building a new work bench and adding new shelves for storage. This will free up some much needed workspace.

CactusJack,
The Buells are great bikes. I enjoyed mine but... the POSSIBLE lack of future factory support worried me some. These bikes use many speciality parts and without these parts the bike is sidelined. I was worried mostly about the swingarm isolators, front engine isolator and heim joints. All of these parts are prone to failure and need to be replaced periodically. Without them the bike is a lawn ornament! My Street Tracker uses no speciality parts whatsoever so that will not be an issue with it.

Hey, nobody rides my KTM! Just kidding! The KTM 950 Adventure is a great bike. It's the best bike I have ever ridden and very functional. The thing will go just about anywhere you point it and I highly recommend getting one. Bring your bike to WV this Spring and we'll get together for a ride. I'm near Morgantown, not far from the mine disaster that is now making the news. Please remember the families of these men and all the miners of West Virginia. Nobody knows what these men and there families go through on a daily basis. I come from a family of miners. ALL and I mean ALL of the men in my family, except for me and my brothers are or where miners. It's the same in my wife's family. My father worked hard in a Consul mine so that we wouldn't have to go down those holes. I thank him for that!

Later,
S Won

"Bring your bike to WV this Spring and we'll get together for a ride. I'm near Morgantown, not far from the mine disaster that is now making the news. Please remember the families of these men and all the miners of West Virginia. Nobody knows what these men and there families go through on a daily basis. I come from a family of miners. ALL and I mean ALL of the men in my family, except for me and my brothers are or where miners. It's the same in my wife's family. My father worked hard in a Consul mine so that we wouldn't have to go down those holes. I thank him for that!"

Hey S Won, I just might be able to take you up on that offer. I had a friend tell me a long time ago that Morgantown is a place I should check out for a ride and I have it on a list of places to go someday. His dad was a miner also many years ago. Thanks. And those miners and their families are in my thoughts and prayers.

Now about your Sportster. The flat trackers I've seen were pretty small frame wise. Have you sat on yours to get a feel and what did you think besides feeling like a little kid on Christmas Day? Cactus Jack

CactusJack,
Morgantown had their first motorcycle rally this past July. It was a small rally but these things usually gather momentum, like a rock rolling down a hill. Hopefully, it will be bigger next year. I have family near Moundsville maybe we could set it up for a weekend that I will be up there so you won't have to go so far. It's up to you! Let me know.

I have sat on the Street Tracker quite a few times. It feels, not to different from my S1W that it is built from. The Buell had a 54" wheelbase the ST has a 56.5" wheelbase. The bike still feels small though. It should be a great ride. My new Buell XB shock came today. Hopefully, I can start mocking that up soon and get on with it.

It's terrible what has happened with the Sago miners. Their families are in our prayers also!

S Won

DUDE WOW really,....................................WOW
no foolin,......................WOW
if you need me, I'll be on the floor
WOW

I have some questions. I too love the dirt track style bike. Been the Springfield Mile many a time. I have an 03 883R with Storz rearsets and Super Trapp XR exhaust. I am interested in those heads, the duall carb,and the swing arm. Are those left side exhaust heads? How much were they? Then for the swing arm. Do they make one that will bolt on a stock HD frame? Then where did you get the intake manifold for the duall Carbs. Love the way the NHRS 1250 kit looks as far as ease of instal and setup. With that a new heads duall carbs might well work.

Thanks for the interest Steve and everyone else,

In case you are just seeing this for the first time, I'll explain a little. I'm building my Street Tracker in the old dirt track XR style. It's a little bit of a modern twist with the Buell engine but I think the bike overall will be awesome. I have had some issues with it lately so, maybe you read about it in the thread. Anyway, that's why it's going kind of slow right now. The XR style heads are from STD. They are the same heads used on the Confederate Wraith and the Mert Lawwill Street Tracker. I got mine from Brian Nallin at Revolution Performance he sources them straight from STD. Mine have Stage 3 porting and are considerably more trick than the stock heads. Yes, they are leftside exhaust and the daul carbs will be on the right just like the XR750. I bought a complete Stage 3 XR kit and everything came with it, including XR style cams from Red Shift. Custom cams are needed if you go this way so remember that! I have decided to make the intakes myself, so they are tight to the frame. Brian can supply the intakes if you'd like. My bike will use a leftside XR750 SuperTrapp SS exhaust. It also came with the kit, as did the dual Mikuni HSR45 carbs. All of it came from Revolution Performance and the cost included everything so, I can't really quote a price on the heads. Besides, I have purchased numerous kits from Brian. He discounted it, so I got a real deal on it. He's a good friend. Contact them or STD. Do a search on Google, they are both easy to find.

The swingarm is custom and came with my frame. I don't believe they make one for a Sportster. It's from C&J Racing Frames.

I hope this helps. Contact me if you can't find them. I sent you an e-mail also.

A short update: The bike is in the process of being cut up right now. I have cut the truss from the swingarm and the shock mount from the frame. I have also purchased a Buell XB shock that is going to be mounted inside the frame in front of the rear tire. The engine is now on the bench in my shop and I am in the process of building it. The project is going slow and I hope to have some pictures soon. Be patient it's going to be worth it!

S Won

Truely awsome looking so far. Can't wait to see it done.

Swon...how about some more pictures especially the left side exhaust and the dual carb set up? BTW, I called c&J, want to go up there and talk about drag frames...we're trying to get together. Thank you.

The dual exhaust just like the rear shock, doesn't fit the bike. The left downtube is in the way of the front pipe. The downtube angles outward and is in the way of the pipe. I will be cutting that front pipe at the first step and having the correct bend tube installed in it. I will also be making the dual IR intake manifolds myself. Revolution sent me the flanges but I think I want to make them out of stainless steel and put a brushed finish on them. I decided to make them myself because, I want them to hold tight against the frame. The Revolution flanges will just be used as a pattern. I'll try to get some pictures up this weekend.

C&J will make a good frame for you. Even with the problems I love mine.

S Won

S Won

Just read the thread. What a Sweet freaking machine. Just like everybody else Cant Wait to see it finished. Sounds like you really know motocycles and also sounds like your spending a ton of dough. What do you think you will have in it by the time your done. I guess the highest compliment I can give you is when its finally finished it Should be on the Cover of Someone's Motorcycle magazine. Keep up the good work and keep us informed And Keep the pictures coming. Man Just Luv it.....

LV

Just read threw the thread. That is one sick looking bike. Can't wait to see the finished product. Its going to be one bad bike.

Thanks everyone,
If I just count up the money I have spent on parts and the value of the parts from my donor S1W, I should have in the neighborhood of 10k in the bike when it's finished. What I really did though is use 2 donor bikes. First, I parted out my 1995 Buell S2. I made a nice profit, a VERY nice profit and used that money to purchase my frame and rear shock. I also sold a NRHS Stage 3 XB/XL1200R Buell engine kit that I had just purchased. The kit was brand new and never used. I made a slight profit on that also, because the guy who bought it was in England and I had gotten a great deal on the kit. It would have cost him much more to purchase it and have it shipped over to England. Anyway, to date I have less than 5k in it and I have about $3000 worth of S1W parts to still sell on ebay. More than enough to buy the rest of the parts I need to finish the bike.

My plan is to have a photographer friend of mine take professional pictures of the bike and send them to IronWorks Magazine. That's the mag I'd like to have it featured in. They have featured numerous XR type bikes over the years. I think they'll like my version. The ULTRA RARE Buell Racing/PM dual calipers, 4-piston rear PM caliper and the triple Braking USA 'Wave' rotors really set the bike over. There are only 9 of the leftside Buell Racing caliper, in the world. I bought mine from a guy that ran a race team.

Tomorrow, I'll be in the shop all day finishing my workbench and building a desk for my computer. After that I'll be starting back on the build and bolting the engine together. One of the first orders of business is to get the new shock mount on the swingarm and frame. Some of the frame mounts need cut off and cleaned up a bit. I'm on my way to town today to get some chromoly tubing to rebrace the tailsection. If you guys know anyone looking for Buell S1W parts you can sent them my way. I have basically everything from the bike except the parts in the pictures. Here's a short list:

S1W frame/no title
Swingram
Fuel tank w/cap
Tailsection
Custom seat
WP Racing forks
Shock
Oil tank
Handlebar controls
Headlight
Carbonfiber flyscreen
Billet axle adjusters
Engine isolators
Swingarm isolators
Engine mounts
Carb cables
Front fender

You'd need wheels, axles, trees, an engine, wiring, brakes, etc... Most of these parts can be purchased on ebay, very cheaply! Sorry to pimp my parts but this is an enthusiast site. Basically, there is enough to give someone a nice start on a very cool dragbike. I'd let everything go for $2000. Ping me!

S Won

Well, I hate to have to do this but... here goes! I have decided to nuke the Street Tracker project. The STD XR heads and SuperTrapp exhaust do not fit the C&J Racing frame properly. I do not want to spend anymore money on the bike sorting out the problems, because I am starting a new house this year for my family. The SuperTrapp exhaust would have to be hacked apart and new pipe would be needed to fix the problem. C&J Racing Frames told me that the heads would work with their frame and that exhaust. It doesn't! The exhaust also did not fit with the side mounted Penske shock. I purchased a new Buell XB shock but the thought of using it instead of the Penske bothers me. If I continued I would need to fabricate a completely new rear suspension. Frankly, I don't have the time or the extra cash to proceed. The STD XR heads and XR cams are on ebay and are going to sell. The reserve was set at $1500 and that was latest bid. They will sell! I was waiting to see if they were going to sell before posting that I killed the project.

I also have decided to part out my S1W to recover my costs. My ULTRA RARE Buell Racing/PM dual front calipers are also on ebay and are probably going to sell Saturday. Check out my auctions to see of you need anything. I have a complete Revolution Performance 1250cc kit, that I will sell for $900. The bike was basically an extra bike for me to use at Rallies and Runs. I really don't need another bike! The bike was started way before we had thoughts of a new house.

Contact me if you have any questions on what parts I am selling or if you need anything.

Thanks,
S Won

Sorry to hear that you are no longer doing this project it looks like a cool project. Send me an email @ deanbruhn at hotmail.com

I am interested in some parts

S won, Thats too bad as all of us were waiting for the finished product!! I understand though how racking up the bucks make yer pockets hurt. I sure wish I had the cash to take it off your hands.

Greg

I can't wait to see more pictures of your build.... I love that tank, btw... awesome stuff.

The project is bust. Cost overruns killed it. The fuel tank, exhaust, brakes and heads are all on ebay right now. You can bid on them!

S Won

Didn't find those heads from ebay, am I too late?

I sold them 2 weeks ago for almost $1800.

S Won

S Won,
Could you list the parts you have that are still available and the price you are looking for on them?


Dean

SuperTrapp XR-750 stainless dual exhaust ($600)
Storz XR-750 aluminum fuel tank ($600)
C&J Racing Frame ($1500)
Penske Racing shock ($700)

Each one of these parts lists for much more than I have put on them. It would be a great project for someone to take over. Unfortunately, a rear suspension would need to be fabbed. I cut the truss from the rear swingarm. The rest is good to go. It's setup for a single rear side mounted shock and the top mount is still on the frame. Dual shocks from a could easily be made to work. Sportster would work. A single shock would work or you could have C&J build a new swingarm for it. I cut one of the support tubes going to the tailsection. It needs to be replaced. The shock hit these part from day one. It would have needed this anyway. I have $2500 in the frame! I'm willing to lose $1000 on it. Same with the rest of the parts. The fuel tank goes for $1000. Check with Storz. For an extra $200 I'd also be willing to sell the Buell triple clamps that are already setup with the correct bearings and are ready to bolt on. I'm putting my Buell back together so if anyone is interested they need to act quickly.

S Won

PARTY POOPER
HA HA HA HA HA

Just goofing ya man, great thread though, it was like a novel.

S Won
I'm really sorry to hear you're giving up the project. I know how tese projects go, one set forward and two back, "it's on back order", it'll be there next week, but it's a little more money...blah, blah, blah. The sadness you didn't finish will probably bother you for a long time, but let it go; go build your house, there will always be another m/c project. My best always,
Doc

You know, I hated to bail on this thing. I was really enjoying working on it and I think it could have been one of the coolest Sportsters ever! But... and that's a BIG BUT, these parts really should have fit. I told them exactly what I wanted to do and what parts I was going to use. They should have made it right but they didn't. I don't understand that! A completely new frame would have needed to be built to fix the problems. I never really gave them a chance to say they would or wouldn't fix it, because everything needed to be changed and then there was no room for the battery, the shock and other needed parts. They did say to send it back, but it was going to be on my dime. Well, none of it was my fault, why should I pay for that! I paid to have it shipped once. I wasn't going to do it again. I imagine it's going to sit right where it is for quite awhile. I have decided to put my 1998 Buell S1W donor bike back together so, I'll be posting something over on the Buell Project thread one of these days. I'm in no hurry on this one either!

On the flip side. The house is moving forward. We are meeting with the manufacturer (SURETIGHT) who will be doing our kit on Friday morning. It will be 28' X 40' and have 2 stories with a full basement. The cost is just under 20k not including the basement. My wife is very happy! My old house will be my new garage. It's 24' X 32' 2 story with a new 15' X 32' addition on the side. Plently of room for bikes, trucks, welders, tubing benders, ATVs, etc...

Here's a couple pictures of my latest project. New Emig Racing clamps and steering stablizer for my KTM 950 S. I'm also doing heated grips, a new radiators screen, new handlebars, dual brakelines, folding off-road mirrors, a new add-on 8 circuit fusebox, and 4 Powerlets for GPS, heated clothing, battery changing, XM Radio, laptop, etc... The difference is that it's almost done! You can still see the ST in the backgound!

S Won
http://swon.zoto.com/img/45/a39bd0a79aad71e325ba46bd8ab6f46b-.jpg

http://swon.zoto.com/img/45/c8b32818f45d858ee4c383ee46d999fa-.jpg

http://swon.zoto.com/img/45/7e97338502f073e6ab1add3ce14f34f4-.jpg

DAYUM, that is one big, mean and nasty ride...

Congrats on the house!!

Thanks AZBiker! We're pumped for the house. Going to assemble it ourselves but contract out the big jobs.

The KTM is a cool ride! I enjoy it more than any other bike I have ridden.

S Won

PS: You guys need to buy my parts!

Sorry to hear you had to bail on the build...You were putting that thing together almost exactly as I would have...sort of living vicariously through you...

Congrats on the house and have fun on the KTM - I really like thier new sportbike too!

Maybe someday you can make it work...

xl1200r,
I was very excited about the Street Tracker but as I have posted the problem with the exhaust hitting both the front left downtube and the rear shock, was too much to overcome. I could have but it would have cost me more money that would have had to come out of the house project. The family would have vetoed that! I have been selling some of the ST parts on ebay and I've done very well so far. The fuel tank and SuperTrapp pipes on up for auction right now. It looks like they will sell for a fair amount.

My thoughts have gone back and forth about putting my S1W back together. The KTM is such a nice bike that I fear the S1W will not get ridden much. I may part it out for house money. If I do, the C&J Racing frame and the Buell engine will be kept for a future project. I may do a Buell powered Adventure type off-road bike, like this!
http://swon.zoto.com/img/45/a6c2399fc3a78d36810f44dcf548e9df-.jpg http://swon.zoto.com/img/45/9922de98b5e12bea89b5ef39a23f924a-.jpg

The frame I have is very similar to this one. I can't help but think, it would be a cool bike to have. I could use cheap 883 parts as it wouldn't need to have big horsepower. If the weight could be kept down to 300# or less, it would be great off-road and on the highway!

Just something I'm thinking about!

S Won

S Won,
Would you be interested in getting rid of the complete s1 front end, brakes and wheel and all and the rear wheel?

Dean

deanbruhn,
Yes, I would! But my parts are going to be on the VERY expensive side! The wheels are an early set made by Marchesini in Italy and have been powdercoated and cleared. Buell used only the good stuff before Harley took them over. After Harley took over the bean counters made them cut costs. The wheels also include brand new bearings that were just installed and they also have new Dunlop 208 tires mounted on them. My brakes are powdercoated and cleared matching 6-piston Buell Racing/PM dual front calipers. The front calipers are ULTRA rare, as only 9 sets got away from Buell Racing. It's the same with the rear brake, PM 4-piston caliper. I have matching German made wave rotors and a larger Nissin dual disc mastercylinder. I don't have any of the stock brakes left. I sold all of that on ebay years ago. I have no idea what all of it is worth. The wheels alone are worth 400 or 500 apiece plus the tires so, you may not be interested! I guess I'd take $1000 for just the wheels and tires but that would be selling them at a loss. The RARE brakes would be in the range of $2000 for everything. I have over $600 in the Braking USA wave rotors alone. These are lightweight high dollar parts. If you want stock parts you'd be better off buy that stuff on ebay. Stock Buell parts are cheap!

I'll take $500 for the S1W forks. They have Buell race springs already installed. I just sold the set of S2 Wp Racing Roma shown in the picture for $600 without the trees.

Here's a picture. It shows most of it! As I said, you're probably not interested. My wife will probably throw this stuff in the coffin with me, because nobody wants them for these prices. That's what I have in them and I'm not going to lose money on them. They can sit on the shelf! The brakes were purchased from a connection of mine in one of the Buell race teams. I only have the good stuff. I also had a complete set of Buell Racing S1W race rearsets that I sold for $100. I sold these for a whopping $250 loss! Never again!

Thanks,
S Won
http://swon.zoto.com/img/45/76b5adc1cf95063894334882ecf4a2ee-.jpg

I hear you there, I thought you still had some of the stock stuff left from the S1. If it was all stock stuff I was gonna say $450 for the whole boat (about the ebay price of the stock buell stuff) of parts, but I can understand your lack of enthusiasm to sell it all that cheap being that its not the stock stuff.

But if you ever want to see them go to a good home and you are sick of looking at em ;)

Wheels, brakes, and complete frontend for $450. Tell me where I can get that deal and I'll get rich on ebay. You may find it for that but I doubt it! I've seen just the forks alone go for $600. If you need that much you'd be better off buying a complete bike and parting it out. Sell the engine and the parts you don't need and get your money back. I paid $3400 for the last Buell I bought and parted it out for over $7500. It's much easier going that way. You have the odd auction with no reserve that nobody bids on and you may get some good prices though. Keep watching ebay. Some of my stuff will be on there.

S Won

I have over $250 in the wheel bearings alone!

S Won