I got my 79 in the end of September and that is when the tear down started. Here is a pic of the greasy dirty frame with the swingarm on top.

http://xlforum.net/photopost/data/500/medium/PICT0233.JPG

Here is a pic of the beautifully sandblasted frame:

http://xlforum.net/photopost/data/500/medium/PICT0237.JPG

Here it is in epoxy primer:

http://xlforum.net/photopost/data/500/medium/PICT0243.JPG

http://xlforum.net/photopost/data/500/medium/PICT0244.JPG

I have since stripped and epoxy primed the oil tank, and rear fender. I then welded the license plate holes and am done with 90% of the body work. Photos to come. I am also keeping an excel spreadsheet diary of my work, hours and dollars spent. More pics coming soon!

Looks like a fine job on the frame so far. Question is do you plan to put it back bone stock? Because as you may know 1979 was a one of a kind year as far as the frame , oil tank , battery location. Parts like pipes and some other items used to be hard to find for the "cant find 79" as she was known. I owned one for a few years. If I can be of help just holler at he I'm around alot and even have some 79 parts. Good luck Kevin.

For the most part I plan on keeping the bike a "stock apperance". I am putting a king tank on it and all the original sheetmetal. Where I will deviate from stock is things like upgraded alternator, ignition system, adding an oil filter, etc. I appreciate the offer of help and misc parts, I will certainly keep you in mind during the build. Keep cheking back as I will continue to post pics of my progress.

Here is the rear fender after stripping it to bare metal;

http://xlforum.net/photopost/watermark.php?file=5608&size=1
http://xlforum.net/photopost/watermark.php?file=5609&size=1
http://xlforum.net/photopost/watermark.php?file=5611&size=1

Here is the pic of oil tank stripped to bare metal:

http://xlforum.net/photopost/watermark.php?file=5614&size=1

Here is the battery tray/oil tank cover:

http://xlforum.net/photopost/watermark.php?file=5623&size=1

Here is the rear fender and oil tank in epoxy primer:

http://xlforum.net/photopost/watermark.php?file=5616&size=1

http://xlforum.net/photopost/watermark.php?file=5618&size=1


Here is the rear fender, I am filling in the overlap of the sheetmetal near the bottom of fender (for a smooth look) filled in the license plate holes top and bottom and I am also filling in any gaps on the underside supports of the fender to prevent moisture.

http://xlforum.net/photopost/watermark.php?file=5620&size=1

http://xlforum.net/photopost/watermark.php?file=5622&size=1

Just got my new king tank and will be taking it to the radiator shop monday for pressure testing and then seal it and I will start the body work. I gave the rest of my parts to a friend who works at a sign shop who will blast the last few remaining parts and I will get them in epoxy primer monday, tuesday. I also have the frame neck bearings being replaced at a local indy shop. When I get it back I will start setting up the gas tank, rear fender and seat for initial fit and then it and the swingarm will be in paint.

Looks like you're doing a great job!
Can't wait to see the finished product.

Looks like you're doing a great job!
Can't wait to see the finished product.


Thanks for the compliment and I am trying to be patient as I cannot wait for the finished product. Yesterday, I was able to get the right side cover in epoxy primer and will finish the body work on it tonight and get it in final primer. I have about another hour or two on the rear fender and it will be in final primer. I am hoping that my friend gets the parts blasted then I can prime them while the filler is drying on the other parts. Then while the primer is drying I can sand the filler and then prime those parts. Sheesh, the coordination of it all!!!!

Lookin good man keep up the good work!!

Biker in Training,
It appears that you are off to a good start. 79's hold a special place with me. Everybody told me I was nuts for building a 79 Sportster but what I couldn't find, I made. The picture below is about 4 years old, click on it. You can see the Peanut Tank was off a 94 1200, matched up the paint scheme and striping on the fenders myself. Had electronic ignition, Just twist the grip hit the starter and she was runnin, every time. I built her for something to do while I was down. At the time I couldn't do much more than ride around the block. My nephew ended up buying her. He went MC for about a year, rode the you know what out of the poor thing all day every day. He bought a Twin Cam and sold the 79 again. The guy that bought her then is still riding her today and still braggin about the way she starts.
She was and is so fine, My 79. Wish I could have made the picture bigger but I have the rest of my allotment tied up elsewhere. Best of luck and I will enjoy seeing the outcome.I have more pix, E-Mail me if you want to see some bigger ones.
4930
stargateops/Grumpy in Florida

I see you are in Florida. I am in Clearwater, have been my whole life. I have been told that I should start with another bike, but this was the first motorcycle I rode ten years ago, I had to have it. I went to a dealer last Saturday and looked at the new bikes and as cool as they are I think they are more modular in design and lack the raw look of the frame, engine etc. Funny the story you tell of your 79 is about the same as this one. My friend owned it and it and then sold it to a friend, it was rode hard all day every day and fell into disrepair, then I got my hands on it and you can see what I have done since I acquired it on September 30th of this year.

Update on progress;
I was lazy the other night and now just got to the body work on the underside of the rear fender (yes the underside) and applied my last skim coat of filler on the outside of the rear fender. I also put my second and last fill on the battery/oil tank cover. I plan on finishing these parts tonight and getting them in high build primer. Today I will have my new king tank pressure tested and over the weekend seal the inside and start on the what little body work it will require. Still waiting on parts from the blaster. Hopefully I get those today/tonight so I can stay busy over the holiday weekend.

Progress Update:

I finished the bodywork on the oil tank/battery cover, it is ready for sealer primer and paint. The new tank passed the pressure test. I got it home and acid etched, cleaned and sealed it with "Kreem" product. After letting it dry for 24 hours I then put it in the parts blaster and blasted the outside of the tank. Got it home and put on a good coat of epoxy primer. I then started the bodywork. I was hoping I would not have much to do but the bottom edge where it was welded is awful. It needed an entire coat along the bottom edge and underneath. Yes, I am doing more body work on the underside of a "panel". I spent most of yesterday sanding and refilling the bottom edge trying to get an even and smooth look. I am shooting for finishing the body work tonight after work and putting on the first coats of high build primer. My buddy is taking the week off at work so that means the parts he has to blast are not going to be ready for a week. I guess that will give me time to finish the gas tank and start on the oil tank. I will post more pics of progress tomorrow.

Here are the two parts I have been working on, hanging the day after Thanksgiving in the sun drying with my 57 chevy in the background.

http://xlforum.net/photopost/data/500/medium/PICT0284.JPG


Here is the gas tank after doing some bodywork. I had to get it in primer to see where I was at. After looking at for so long I needed a refreshing look at it!!

http://xlforum.net/photopost/data/500/medium/PICT0293.JPG

http://xlforum.net/photopost/data/500/medium/PICT0292.JPG

Here is the oil tank battery cover with body work and in its final primer.

http://xlforum.net/photopost/data/500/medium/PICT0269.JPG

http://xlforum.net/photopost/data/500/medium/PICT0295.JPG

Tonight I am going to finish the body work on the gas tank, after seeing it wet in primer, I have little left to do.

Here is what I am starting with, now that I know how to post pics I should have put this one first!!

http://xlforum.net/photopost/data/500/medium/PICT0031.JPG

That '57 chevy is, ..., gee, like no words. Looks so good it hurts to look at it.

Thanks alot IronMick, compliments like that make the 15 years I have owned it and all the money I spent worth it. Here is another shot of it in its full glory.

http://xlforum.net/photopost/data/500/medium/canadanewyork_003.jpg

http://xlforum.net/photopost/data/500/medium/canadanewyork_004.jpg

I plan on painting my 79 the same color as my chevy bright red!!

I am really impressed. The work in progress that I am watching unfold on the 79 is Un-Frigging Believable.... I try hard to do fine work on anything I do but I believe from what I'm seeing, your work is genious. We gotta meet up soon. I have to see if some of it will rub off on me. Using the color of the 57 on the bike is perfect, Red's my color too.
The 57 is killin me it's so nice. I'd love to do some digital pictures of it with a cool background, with you're permission of course.
Stargateops/ Grumpy down in St. Pete.

You are too kind!!! We can certainly meet up, maybe Friday or is it Saturday at Biff Burger. You are more than welcome to take photos of the chevy (which I will drive to Biff Burger)and when I get done, the 79. Thanks again for the compliments!!! More pics coming soon and hopefully some good progress tonight after work.

Just by looking at that 57', the sporty is gonna turn out real sweet. You do some great work!! Can't wait to see the bike when its done.

Greg

Outstanding! I'm turning green!
:clap
I'm doing a ground up rebuild of a '72 FLH and I'm not nearly that far along yet. Looks great!
Good Luck
Bob

Since my last post I have had some good progress with the paint and body work. Since the limit is three images a day you will have to wait until tomorrow to see pretty red paint.

Here is a pic of part of the front fender, kick stand, “ham can” air cleaner and exhaust support bracket after being sandblasted. You can see where in humid Florida surface rust starts almost immediately. I re-blasted and epoxy primed those parts immediately.

http://xlforum.net/photopost/data/500/medium/PICT0299.JPG

Next is the gas tank. The king tank I bought needed more than just a skim coat. I had to recreate the entire bottom edge and smooth and straighten the entire tank. I used all-metal which is the silver material all over the tank (the primer is gray).

http://xlforum.net/photopost/data/500/medium/PICT0002.JPG

http://xlforum.net/photopost/data/500/medium/PICT0005.JPG

I have at this point in disassembly and paint and body work 140.5 hours and about $800 in body supplies and miscellaneous tools and new bike parts. I have at this point completed body work on front fender, rear fender, gas tank, and ham can air cleaner. I have painted all those parts plus the kick stand, swingarm, and exhaust support. I applied what little paint I had left over on the frame and will be spending another $120 on more paint and clear to finish the frame. I started on the oil tank by welding in some fittings, but have minor leaks around the welds. It is on the back burner until I can give it my undivided attention. Thanks for your compliments and check back tomorrow for after I upload more pics.

As promised I would post pics of painted items. First pic is of the gas tank mocked up on the frame just before final primer. The other two are in paint and clear.

http://xlforum.net/photopost/data/500/medium/PICT0301.JPG

Swingarm:

http://xlforum.net/photopost/data/500/medium/DSC_0672.JPG



Gas tank, rear fender and front fender:

http://xlforum.net/photopost/data/500/medium/DSC_0674.JPG

I reported how many hours and dollars, and I almost forgot the most important stat:

Total number of beers: 384

Over the weekend I accomplished a few more things on my restoration.


Here is the frame painted:


http://xlforum.net/photopost/data/500/medium/DSC_0706.JPG

The frame with gas tank and oil tank battery cover installed:

http://xlforum.net/photopost/data/500/medium/DSC_0684.JPG

Here is the rear fender mocked up on the frame:

http://xlforum.net/photopost/data/500/medium/DSC_0690.JPG


Started polishing the aluminum and came up with a cool replacement for the reflector in the rear fender support. I will upload tomorrow when I am allowed my three more photos.

Well, nice eh.

Those pics are just amazing and the progress; keep the photos coming :)

An amazing transformation!! Excellent pics. Thanks for sharing them!! :clap :clap :clap :clap

Looking good there man. I am interested in how long and how much do you think this will take out out of your stash can to re do this?

Lookin' good! :smoke

Looking good there man. I am interested in how long and how much do you think this will take out out of your stash can to re do this?


I am keeping a log on an excel spreadsheet that I keep track of my hours and dollars. I think the last time I looked I had about 175 hours (started Sept 30, 2005) and about $1000. That $1000 included the motorcycle jack and a few miscellaneous tools. The rest of the money is paint supplies and a few new parts. Thanks everyone for the compliments!!!

looking good indeed, I likes the old red shoebox also

Some more pics:

http://xlforum.net/photopost/data/500/medium/DSC_0712.JPG

http://xlforum.net/photopost/data/500/medium/DSC_0723.JPG

Some more pics:

http://xlforum.net/photopost/data/500/medium/DSC_0712.JPG

http://xlforum.net/photopost/data/500/medium/DSC_0723.JPG
I likes Fosters too:D :drinkbeer :cheers :chtwo :thinkbeer

I likes Fosters too:D :drinkbeer :cheers :chtwo :thinkbeer

I got those when I worked at Outback steakhouse. If you look closely you can see the fosters great white hanging from the ceiling with an oil can in his mouth!!! Now if I can get a kegerator or beer tap in my garage!!

looks good!! im building a 79 myself!!

More progress:
Here is a pic of the dirty front wheel:

http://xlforum.net/photopost/data/500/medium/DSC_0701.JPG



Here is a pic of the sandblasted wheels.

http://xlforum.net/photopost/data/500/medium/DSC_0705.JPG

Since we are only allowed two photos I will post the primed and painted pics tomorrow.

That '57 is a freakin' thing of beauty, and it's looking like the '79 will be also. Nice work! Very nice!

Here is the front wheel in epoxy primer:

http://xlforum.net/photopost/data/500/medium/DSC_0709.JPG

Here is the front wheel painted blacK:

http://xlforum.net/photopost/data/500/medium/DSC_0713.JPG

It has been a while since I updated my progress. Well I have had little or no progress due to lack of funds. However, I dropped my motor off at an indy in January and just picked it up yesterday. :banana

The cost was $2086.45 and my awesome brother paid the tab. Lots of new parts and the coolest of them all is the new kickstart kit they installed. I will list the invoice later. Bottom line is even though it took 8 months they were cool about it and I feel I got a good deal. They also agreed to when I assemble the bike, fire it up and do all necessary adjustments.

I will post pics when I get lower resoulution shots, my wife took some photos and the files are about 1.5 MB, way too big.

Pic as promised.

http://xlforum.net/photopost/data/500/medium/DSC_1099.JPG

Man I love that Chevy. I had a friend in highschool that took the money he saved up for a car and paid 300 or so for a trashed 50-something bel air, in about a year or so he had it running, and even though the body work wasn't done I still thought it was the coolest car at our school. If I had the funds and time to have a project I couldn't decide if I'd want to do an ironhead, classic car or classic truck.

By the way, I live in Seminole so I'm really close to you, would you mind saying who did the engine work? No one in my family has had anything go wrong with their bikes yet, but for stuff like tires there has to be a better place to go to than Fletchers. The prices there and the 1 month+ wait is just a little extreme to just get new tires.

This is a great project. progress pics are always great. cant wait to see the completed pics

By the way, I live in Seminole so I'm really close to you, would you mind saying who did the engine work? No one in my family has had anything go wrong with their bikes yet, but for stuff like tires there has to be a better place to go to than Fletchers. The prices there and the 1 month+ wait is just a little extreme to just get new tires.

I went to a place on Ft Harrison and Belair road, the indy is called Manor Cycle. Fletchers pointed me to Manor when I inquired into my ironhead rebuild. I could not be happier with the work done. The other good indy near us: I am in Largo, is Performance Twin on Ulmerton Road just east of Starkey behind Foxy-o-Tooles. Much better than the dealer, I guarantee they wont need a month for tires. I had them mount some D401's on my freshly painted black rims and look awesome. It took them about a week having them disassemble the rims, me sandblast and paint, them remount with all new parts, sprocket, rotors bearings etcetera.

Thanks for the compliments and hopefully some assembly pics soon.

INVOICE:

10 hours labor $600
Parts $1329.95

Parts list:
1 sprocket cover 99.85
1 timken bearing 39.99
6 cam shims 3.00
1 gasket seal kit 40.00
4 cam bearing 27.16
23 m/s roller bearing 18.49
1 tranny bearing race 40.00
1 c/s bearing 9.95
1 set pistons .20 over 80.00
1 set piston rings 29.95
2 spark plugs 5.00
2 lok tabs 2.00
1 clutch gear good used 50.00
1 clutch cable 28.95
1 tranny sprocket 15.00
1 twin tech ignition 279.80
1 head bolt kit 45.27
1 set rocker oil lines 13.50
1 rocker box mount 16.00
1 top cylinder mount 13.50
1 presto starter 191.85
1 rear motor mount 20.00
1 kicker shaft 24.95
1 starter crank gear 48.95
1 starter ring gear 82.95
1 crank spring 12.95
1 crand spring stud 4.95
1 kick gear kit 42.95
1 kicker arm H-D 29.95
1 kick pedal 12.95

I have the front motor mount and an alternator on order.

get hot, lets see it done:p

http://xlforum.net/photopost/data/500/medium/DSC_0239.JPG

http://xlforum.net/photopost/data/500/medium/DSC_0237.JPG

I started to re-assemble this on-going project. First problem I ran into was the rear motor mount. Bought a new one. Second problem was the bottom bolts on the motor were on backwards. Had to repaint the frame as it was destroyed. Installed the motor with new hardware. Installed a new alternator and regulator. Installed new 11.5 inch progressive shocks, went to install the rear wheel and ran into a problem. The bolts that the indy used were to big and were hitting the rotor and they had the spacers in backwards, short spacer is supposed to be on the rotor side, long is on the sprocket side. Took it back and he put in new bolts that still were too big so I just took out the lockwashers and used loctite on the bolts. Luckily I was able to find the rubber grommet that goes in the caliper mounting bracket on the underside of the swingarm. One catalog had this part for $23 wtf? Now I need to get the front forks rebuilt. More money.