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freeidaho
28th December 2010, 21:25
Howdy,
I thought I should document the mild build going on at my house. I have learned a whole lot here at the University of XLForum. Thanks for that.

I bought a 2006 883L from Craig's list with 3200 miles, garage kept, and for a dynamite price. It has data-dots, the HD security system, and the accessories shown.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1352.jpg

This is my first bike in 28 years. I rode every day from age 8 to age 32. But when I moved to Kali back in the early 80's, I sold 5 motorcycles and hadn't ridden since.

Along about September I was making a list of all the things I could buy that would add joy to my life. And since I can't afford a mistress, a motorcycle was next on the list. ;) And I always buy American first, so right when I started my research, this Sportster showed up on Craig's list.

I know, I know, it is a lowly 883, and a lowly rubber mount, but I like it.

kr

freeidaho
28th December 2010, 21:30
Howdy,
As I was driving it home at 35 degrees in the rain, the choke knob decided to self destruct. So here is my first change on the bike.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1349.jpg

The aluminum knob took about 15 minutes on the lathe, and works great.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1351.jpg

kr

cowboy770
28th December 2010, 21:34
I know, I know, it is a lowly 883, and a lowly rubber mount, but I like it.
kr

Why lowly?? I would say the rubbermount is a better engine but that's just me.

freeidaho
28th December 2010, 21:37
Howdy,
Next was a final drive cover change. If one needs to change a belt on the road this cover makes it very hard. The right footpeg needs to come off to get the cover off. Besides, I just like the mechanicalness of it all.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1392.jpg

With a bandsaw and a sanding drum we get:

http://www.parmarng.org/freeidaho/MiscHost/IMG_1395.jpg

And here is the finished result.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1396.jpg

Now I may have to buy a belt on the road in some podunk town, but I can put it on myself.

kr

freeidaho
28th December 2010, 21:59
Howdy,
It seems like 25% of all the threads on this forum are about exhausts. They are clearly one of the things that add character to a Sportster. And many hold strong opinions about what is correct and what is not.

And although I will make a 2 into 1 at some point, I'm starting out with the Gronk mod on the stock mufflers. My thanks go out to Sir Gronk. Because he was willing to show how to get the muffler apart and get the baffle out, this becomes a modification that is low risk and easy to do.

$42 off of ebay got me a slightly used set of mufflers to play with. I plasma cut the baffles out of the mufflers and spent a couple of hours drilling holes in the baffles. The original 1/8" holes were enlarged to 5/16", and then lots more holes were added. The original holes had a cross sectional area of 2.9 square inches. The new baffle now has 20.3 square inches of holes.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1440.jpg

I just welded the baffles back into the mufflers, but don't have them on the motorcyle yet. So standby for a sound bite.

For those doing this modification, there are two tough parts. One is to clean up the holes after they are drilled. I had a grinding stone small enough to fit into the baffle on the end of a 12" rod, so that worked for me.

The second hard part is forming the bell on the end, so the baffles can be welded back in. I heated the end of the baffle and forced it onto the round end of a large ball-peen hammer. This worked great, but I would suggest doing this part before the holes are drilled. The baffle has so many holes in it that it is probably weakened. So doing the bell before the drilling will make sure the baffle is not damaged by forming the bell. I had no distortion of the baffle during this process, but was very careful about putting force on the baffle.

kr

freeidaho
28th December 2010, 22:13
Howdy,
Two days ago the rear fender got shorter. Can you tell the company I work for shuts down for two weeks over Christmas?

http://www.parmarng.org/freeidaho/MiscHost/IMG_1444.jpg

Those of you that shoot competitively will notice the use of target paster tape ;)

http://www.parmarng.org/freeidaho/MiscHost/IMG_1448.jpg

I used a jig saw to do the cutting. I prefer it over the cut off wheel for some things.

kr

freeidaho
28th December 2010, 22:28
Howdy,
Next is to move the turn signals to the rear fender. I bought a set of Kriss Products, turn signals and running lights for the rear.

But as you know there isn't really much of a flat spot on the rear fender after it is cut. So I made a dimple tool. Here the tool is inserted into a hole drilled for the turn signal, and tightened up. This makes a 1" round flat spot in the fender centered on the drilled hole, and gives one a handle to do some bending.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1452.jpg

Then one can "steer" the tool to make a flat spot on the fender point the right direction to attach the turn signal to.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1449.jpg

Here is the tool in the open.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1450.jpg

And finally, here is the fender with the turn signals mocked up.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1455.jpg

My custom tail light should be here by the first of the month. Then I will have three stop lights to help wake up the other drivers. I have designed, but not yet built a brake light/turn signal coupler and modulator. That will give me even more visibility.

kr

GophersAndCheese
28th December 2010, 22:50
Nice work so far! I think I need to find a friend with a machine shop.

freeidaho
28th December 2010, 22:58
Thank you!

What has worked for me goes as follows. Whenever you have a job to do, buy the tools and do it yourself. Apply this to mufflers, washing machines, garbage disposals, tune ups, new patio, chainlink fence, plumbing, etc. You get the idea. Just remember to buy good quality tools. You don't need Snap On, but Harbor Freight won't cut it.

I have found one can buy the tools and parts, screw it up once and still come out ahead dollar wise. And when you are done, you still have the tools and the experience. This approach applied over a lifetime will net you several tool boxes full of tools and the skills to go with them.

And with the internet, you can find information on almost any job. It is much easier than in the past to get educated before tackling a new job.

kr

Blaze
28th December 2010, 23:06
Subscribed!

freeidaho
28th December 2010, 23:47
Blaze,
I love the second quote in your signature line. I'm stealing it for work.

"In the world of management, telling the truth becomes an act of revolt."

kr

Blaze
28th December 2010, 23:50
I stole it from the Wikileaks thread...

jharback
29th December 2010, 01:06
Nice write up!

wedge
29th December 2010, 12:03
Excellent thread. Good detailed photo's. I like the sprocket cover. I don't run a sprocket cover at all, and I am thinking of cutting the cam cover to match the rear of the block, but I may rethink doing it your way now that I have seen it. Did you remove the other belt guards as well?

freeidaho
29th December 2010, 13:07
Wedge,
Thank you.

Yes the belt guards are in the "Craig's List" pile.

Thanks again,

kr

wedge
29th December 2010, 15:59
Wedge,
Thank you.

Yes the belt guards are in the "Craig's List" pile.

Thanks again,

kr
OK keep the pictures coming, this is definitely my kind of bike.

Is Idaho currently a dictatorship?

freeidaho
29th December 2010, 16:59
Is Idaho currently a dictatorship?

No the FreeIdaho comes from the generous freedoms we have here in Idaho. We have lots less government than most places and that government is very conservative, and hence more freedom.

kr

Rico 05R
29th December 2010, 17:59
no the freeidaho comes from the generous freedoms we have here in idaho. We have lots less government than most places and that government is very conservative, and hence more freedom.

Kr

viva freedom!!!

Rickyrocket
29th December 2010, 18:32
can you post a pic of your rear fender mounted,I like the way its been "BOBBED"instead of being chopped in half!

sportsterpaul
29th December 2010, 18:49
Nice, I like your train of thought and ingenuity. Best wishes for the New Year.

beano
29th December 2010, 18:53
subscribed !!!...b.

redi2ride
29th December 2010, 19:07
Your project is lookin good. If you live near Boise I would love to take a ride to see it in person. My Bro and I are doin a lil project ourself. hopefully it will be rolling this spring.
Hit me up if you are going to any local rides.

beornj
29th December 2010, 19:08
I'd just like to point out that I live in Boise, ride a sportster, know my way around Impact Guns, and could use a friend with a machine shop. :wonderlan

freeidaho
29th December 2010, 19:23
Your project is lookin good. If you live near Boise I would love to take a ride to see it in person. My Bro and I are doin a lil project ourself. hopefully it will be rolling this spring.
Hit me up if you are going to any local rides.

Redi,
I live in Eagle, which is a bit north west of Boise. There is a whole winter of small things planned. I still have a different tail light, 4.5 gallon tank, pillion seat, front turn signal relocate, bars from a custom, tach, steel tool box, homemade NRHS type air cleaner, tail light modulator and some powder coat to do.

I'd love to meet and look at each other's rides. But right now my motorcycle is apart enough I can't ride it.

I'm also researching bikini fairings, dual headlights, and at some point will make a short "in town" and taller "long trip" sissy bar.

The 3.3 gallon tank, 3.3 gallon solo seat, 2up seating and sissy bar/luggage rack in the original picture are in the "Craig's List" pile.

Where are you located?

kr

freeidaho
29th December 2010, 19:25
I'd just like to point out that I live in Boise, ride a sportster, know my way around Impact Guns, and could use a friend with a machine shop. :wonderlan

If you shoot IDPA, LRTR, or 3-gun, we have probably already met....

kr

redi2ride
29th December 2010, 19:38
N. Nampa Off franklin & Cherry

davev1954
29th December 2010, 19:43
I'd just like to point out that I live in Boise, ride a sportster, know my way around Impact Guns, and could use a friend with a machine shop. :wonderlan

Cool- we appreciate the support of our store and shooting range. We should plan an open house this summer- everyone who rides their Sportster in will get a free range pass and we'll have some free guns and free ammo to try out- we could also have a BBQ or something- sound good?

beornj
29th December 2010, 19:51
Cool- we appreciate the support of our store and shooting range. We should plan an open house this summer- everyone who rides their Sportster in will get a free range pass and we'll have some free guns and free ammo to try out- we could also have a BBQ or something- sound good?

I'm there.

maddenj
29th December 2010, 21:09
Cool- we appreciate the support of our store and shooting range. We should plan an open house this summer- everyone who rides their Sportster in will get a free range pass and we'll have some free guns and free ammo to try out- we could also have a BBQ or something- sound good?

I'm planning on riding to a buddies house in northern Idaho this summer, is the invite open to SoCal residents....

if the timing fits...

freeidaho
30th December 2010, 10:00
can you post a pic of your rear fender mounted,I like the way its been "BOBBED"instead of being chopped in half!

Ricky,
Not mounted yet, but mocked up so I could get a picture for you. I am calling it a "trim" since bobbed and chopped are over used enough that their meaning is unclear. In my way of thinking this is the shape it should have been from the factory. But that may just be me.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1460.jpg

The look will change some more when the tail light gets here.

kr

redi2ride
30th December 2010, 10:43
Cool- we appreciate the support of our store and shooting range. We should plan an open house this summer- everyone who rides their Sportster in will get a free range pass and we'll have some free guns and free ammo to try out- we could also have a BBQ or something- sound good?

If you want it to go big, Call up Bree at cruisinbikerwear.com Her lil store is good at bringin bikers together.She is good people too. I will be there for sure. I'm new to guns and am planning on buying one soon. any retailers you suggest ?

By the way Cruisin moved to Meridian right next to Busted Shovel.

freeidaho
30th December 2010, 10:57
Redi,
Definitely stop by Impact Guns, they are good people.
http://www.impactguns.com/store/boise_map.html

They have wide selection, and good sales folks too. They are a gun shop, small gunsmith, and indoor shooting range. You can rent guns there too and shoot them on the range. So you can try out some different types of handguns before you buy. They also have training, and an indoor IDPA program, which is a low pressure, great fun, self-defense oriented shooting sport. http://www.idpa.com

kr

davev1954
30th December 2010, 11:15
Redi,
Definitely stop by Impact Guns, they are good people.
http://www.impactguns.com/store/boise_map.html

They have wide selection, and good sales folks too. They are a gun shop, small gunsmith, and indoor shooting range. You can rent guns there too and shoot them on the range. So you can try out some different types of handguns before you buy. They also have training, and an indoor IDPA program, which is a low pressure, great fun, self-defense oriented shooting sport. http://www.idpa.com

kr

I couldn't have said it better myself! Hope to meet you Idaho guys one day, maybe when we do a XL shindig this summer at the store.

Good idea about the bikewear contact- I'l look into that- we have plenty of room over at Impact to do a big event.

And I can recommend a good gun retailer- Impact Guns! And the owner rides a Sportster...

freeidaho
30th December 2010, 20:51
Dave,
Are you based in Utah?

kr

davev1954
2nd January 2011, 20:09
Dave,
Are you based in Utah?

kr

Yea, our main office is in Ogden.

I agree with your your comment about the rear fender. Never really liked the stock fender. I once saw a smooth, rounded fender- cut high- exposing the tire- always that that was the correct look for a sporty. I'm watching what you do to yours.

Rickyrocket
2nd January 2011, 20:48
I like the trim you gave your fender,it works,the directionals are fronts that you used on the rear ?

Durockrolly
2nd January 2011, 20:50
I stole it from the Wikileaks thread...

I've always liked your sig.

freeidaho
2nd January 2011, 21:03
I like the trim you gave your fender,it works,the directionals are fronts that you used on the rear ?

Ricky,
The turn signals are Kriss Products. They have dozens of options. These are red rear (2020-0154) and amber front (2020-0153) versions both with turn and running lights. The wires run through the mounting bolt on all of mine.

This bike has a dangling front signal when I got it. A new one was $70 from HD. So for about $100 I got a matched set of 4 in black, with running lights added to the rears. The fronts will be relocated to the bottom triple clamp when my "C" handle bars come.

kr

redi2ride
3rd January 2011, 11:33
I work at Idaho Doabetes and Endocrine associates if any one around here wants to do a Diabetes fund raiser I would be game to help out.Make it a cause.. More people show up.

freeidaho
8th January 2011, 05:01
Howdy,
A bit of progress on my air cleaner this week. Recall that I am making a smooth flowing air cleaner. Here are the plans http://www.parmarng.org/freeidaho/MiscHost/SportsterAirCleaner.pdf

And here is the progress:

http://www.parmarng.org/freeidaho/MiscHost/IMG_1493.jpg
The raw front and back plates as well as the horsepower disk.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1502.jpg
The horsepower disk is cut to size and the ramp is machined in.

Lots more machining steps left.

kr

freeidaho
15th January 2011, 00:54
Howdy,
A bit more progress on the air cleaner. I gouged out about half of the throat. It also has the three carb mount holes, vent hole, two mouting holes to mount it to the two heads using the old crankcase vent holes, and another hole for clamping the front plate on.

http://www.parmarng.org/freeidaho/MiscHost/IMG_1509.jpg

Lots left to do.

kr

freeidaho
30th January 2011, 22:03
Howdy,
A bit more progress on the tail light and fender.

This is a picture of the inside of the fender, with the tail light bracket sitting in its proper position.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0005.JPG

The next two are the very first mounting of the tail light.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0006.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0007.JPG

This is my third try at a tail light, and I think I like it. It has two independant stop and tail light bulbs, so I wll have a total of 4 stop lights.
kr

Rico 05R
30th January 2011, 23:23
I think the taillight turned out great. Looks good.

jjw
30th January 2011, 23:38
Nice lookin' tail light, almost looks like a pair of oakly sunglasses.
Just thinkin' out loud here, what if when you cut the fender you cut it with a radius on the flat. IE the fender would match the slight radius on the tail light. Just a thought, it looks good. I'll be watching the breather plates evolve.

freeidaho
30th January 2011, 23:45
I think the taillight turned out great. Looks good.

Thank you,
kr

freeidaho
30th January 2011, 23:46
Nice lookin' tail light, almost looks like a pair of oakly sunglasses.
Just thinkin' out loud here, what if when you cut the fender you cut it with a radius on the flat. IE the fender would match the slight radius on the tail light. Just a thought, it looks good. I'll be watching the breather plates evolve.

Thank you,
Actually the fender is trimmed to provide an even gap between the tail light and the fender. It is only really visible from directly rear.

kr

myndset
31st January 2011, 08:48
I'm there.

Me too.

myndset
31st January 2011, 08:52
Howdy,
A bit more progress on the tail light and fender.

This is a picture of the inside of the fender, with the tail light bracket sitting in its proper position.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0005.JPG

The next two are the very first mounting of the tail light.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0006.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0007.JPG

This is my third try at a tail light, and I think I like it. It has two independant stop and tail light bulbs, so I wll have a total of 4 stop lights.
kr I like it man. Good job.

freeidaho
5th February 2011, 00:19
Howdy again,
Got a bit more work done on my air cleaner. Still a few more machining operations necessary, but it definitely looks like a velocity stack now.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0011.JPG

kr

Rico 05R
5th February 2011, 00:23
Excellent, keep the pics coming.

freeidaho
5th February 2011, 00:58
Thank you,
kr

freeidaho
5th February 2011, 22:38
Howdy,
The rear fender is done with fabrication. I added mounting tabs and gussets to the tail light bracket. And the bracket is done.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0013.JPG

Then two studs were welded into the inside of the fender so the tail light is mounted without any bumps on the exterior of the fender. Now the fender is completely slick.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0014.JPG

Next to tackle is the wiring, and then the fender can go to the powder coater when the rest of the parts are ready.

kr

freeidaho
6th February 2011, 01:32
Oh Yeah,
I picked up my new hat at the Embroidery shop.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0018.JPG

kr

kg8270
6th February 2011, 01:47
keep up the good work

freeidaho
6th February 2011, 01:51
Thank you,
kr

freeidaho
11th February 2011, 01:06
Howdy,
Just a bit more progress on the homemade air cleaner. The velocity stack is done. The front and back plates are next.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0020.JPG

kr

freeidaho
2nd April 2011, 22:33
Howdy,
A bit more progress. I bought a Lepera Sorrento seat. After paying nearly $400, and reading here and there about seat thefts, I started worrying about a $400 bill available to anyone with a Leatherman or 7/16" wrench in their pocket.

I asked about this here on the XLForum and learned that some people are using security bolts. After weighing that, I went another way.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0049.JPG

Here are the fabrication pictures
http://www.parmarng.org/freeidaho/MiscHost/IMG_0038.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0040.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0043.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0044.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0053.JPG

kr

freeidaho
16th April 2011, 23:03
Howdy,

The handlebars from a Custom are going to be excellent for my Sportster. The tank, fender and miscellaneous are at the powder coater, and I'm getting ready to mount a fairing. Found some New Old Stock of the bikini fairing I liked in the 80's and found a good deal on EBay.

http://www.parmarng.org/freeidaho/MiscHost/ResearchShoei FM-2.jpg

Of course this requires a 7" headlight that was already planned anyway, which is in the works soon, and I just got done mounting my new tach on the eyebrow bolt locations. Another EBay killer deal.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0086.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0088.JPG

The work continues,

kr

sportsterpaul
17th April 2011, 03:03
Coming along GREAT!! And that fairing I now remember well and would probably work out perfectly on my '06 R. Guess I'm going to have to hunt one up!

freeidaho
17th April 2011, 03:25
Paul,
The place I got mine from has lots of them. Try an EBay search for "Shoei FM2". From holding it up to the front end about a hundred times, it looks to give complete coverage of the hands and arms with the bars from a Custom.

I am very jealous of your "R", you are a lucky man.

kr

redi2ride
17th April 2011, 06:34
freeidaho. did you get out to ride today? nice for once huh?. kinda interested to see what that fairing is gonna look like.

freeidaho
17th April 2011, 14:48
Redi,
No riding for me till the tank and fender come back from the powder coater. :(

I saw you got out a bit. Excellent.

kr

damiller_77
17th April 2011, 16:07
I just found your thread, you are pumping out some great work. Wish I had your skills in the shop. Keep the progress reports coming, can't wait to see it all put together.

freeidaho
17th April 2011, 17:56
Dave,
Thank you. Wish I had a 1200 !

kr

sportsterpaul
21st April 2011, 05:49
Ken: Got the fairing yet? Was curious how it looked mounted. I have access to Dealer pricing through Dixie International, who I learned distributes those fairings. I have the 4.5 gal. tank off of a Custom Sporty and wondered how the squareness of the fairing would meld with the roundness of the tank? Also seems like the handlebar extensions might line up well with the drag bars and 4" risers I run. Isn't Friday coming up soon?

freeidaho
21st April 2011, 16:02
Paul,
I have the fairing. Dixie is where I got mine from EBay. I have held it up to the front of the motorcycle a few hundred times, but it is hard to tell from arms length. And my tank is at the powder coater. It supposed to be done by Friday, but this is the third Friday in a row it was promised. So I have diminished faith.

I need to mount a 7" headlight, since that is the size of the opening in the fairing and is also used to moung the bottom of the fairing. The bracket bases are on the way, but not here yet. If they arrive by the weekend, I may get to create bottom mounts and mockup of the fairing in position on the motorcycle. I will post a picture or two when all the ducks aline.

I have standard risers and bars from a Custom, so the grips may end up in roughly the same place as on your motorcycle.

kr

sportsterpaul
21st April 2011, 16:34
Your grips are probably close. When I changed mine out I'm still close to stock height, only my guages are 4" higher and easier to watch while running down the road. I'm thinking with the fairing and handguards my lower arms will do much better on the sub-zero runs. Thanks for the reply. Oh, and keep in mind that switching to a 7" light isn't bad but look for a late model big twin and go for the computer enhanced reflector- way better than the lens's with lines.

freeidaho
21st April 2011, 17:15
Paul,
Thanks,
kr

sportsterpaul
8th May 2011, 04:39
Ken: Fairing mounted yet? Curious for a look see...................................

freeidaho
8th May 2011, 05:00
Paul,
I have had the fairing partially attached to the bike but without the windshield. The lower fairing mounts have been made and they work well. Everything is at the powder coater right now. By now I have about a 5 day wait for the brackets to come back, if the powder coater keeps his schedule.

Sorry I did not take a picture when the fairing was partly mounted. A failure on my part for sure. Too many irons in the fire, worrying about an alternate mount for the front turn signals.

I can say that I like the way it fits. I expect good coverage. I also need to get the "Low" forks converted to standard, so that the fender does not come up and smack the bottom of the fairing. I may be lowering my fender to barely off the tire for some clearance.

Sorry to disappoint you. I will post pix when the brackets come back.

kr

Ironbutt1345
8th May 2011, 14:15
Great work, very original. My wife has a 2003 883C that is a solid mount. She makes fun of the way the motor on my 2005 1200C rocks back and forth at a stop light, but I suspect she wishes she had a rubber mount too!

sportsterpaul
8th May 2011, 23:52
Ken: Never a disappointment, if I've learned anything by growing this old it's everything in it's due time.....

freeidaho
14th May 2011, 23:41
Howdy,
Got 14 items back from the powder coater so progress is being made.

Just mounted up the 7" headlight and lower fairing bracket. They are powder coated black since with the fairing on, they should be subdued.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0113.JPG

Here is the fairing mocked up but no top mounts.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0115.JPG
http://www.parmarng.org/freeidaho/MiscHost/IMG_0116.JPG
http://www.parmarng.org/freeidaho/MiscHost/IMG_0120.JPG
http://www.parmarng.org/freeidaho/MiscHost/IMG_0121.JPG
http://www.parmarng.org/freeidaho/MiscHost/IMG_0122.JPG

kr

Rico 05R
15th May 2011, 02:29
Looking good, can't wait to see it when it's finished.

sportsterpaul
15th May 2011, 05:33
Ken: Congrats, you have scored a very origional look to your build, and I'm liking the way the fairing flairs back to the grips. Definitely one of a kind!

freeidaho
15th May 2011, 15:11
Guys,
Thank you for the kind words. I have walked past it a couple dozen times, and I like it.

If I get a break, I may get to ride it tonight, sans Fairing.

Thanks again,

kr

freeidaho
22nd May 2011, 04:05
Howdy,
I rode my Sportster today, after a winters work. Pictures to come tomorrow.

But tonight I want to thank Sir Gronk again. My Gronk++ modification
http://www.parmarng.org/freeidaho/MiscHost/IMG_1440.jpg
is outstanding.

When I first fired it up, I thought, Hmmm, not much difference, maybe this isn't for me. But after putting 50 miles on today, this modification is perfect. It has a deep aggressive sound when working hard, but settles down to a mild delicious sound at idle. The people in cars around me can hear the motor, but it is not obnoxious.

Thank you Gronk ! ! !

kr

freeidaho
22nd May 2011, 19:55
Howdy,
An update with pictures. Recall this started life as an 883L.

Major changes are: 4.5 gallon tank from a Custom. Low rise handlebars from a Custom on the stock 2" risers. HD Tachometer. Seven inch headlight with brackets for an upcoming bikini fairing project. Trimmed fender. Relocated front and rear turn signals. Cat's eye tail light. New rear shocks. Cut final drive cover. Le Pera seat with lock. Gronk++ modification for the mufflers.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0125.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0126.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0127.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0128.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0129.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0130.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0131.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0132.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0133.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0134.JPG


I don't know what style this is. It is just a collection of features that make sense to me. More to come over the summer, but I can RIDE now ! ! !

kr

Rico 05R
22nd May 2011, 22:19
Looks great, I really like the taillight setup.

freeidaho
22nd May 2011, 22:26
Rico,
Thank you Sir!
kr

sportsterpaul
23rd May 2011, 01:31
Ken: it's amazing just how popular the 4.5 gallon tank has become, and with your seat it pulls together well. Seems to be a never ending upgrade. Good for you, enjoy and get us some feedback on you shocks and seat performance, thanks.

freeidaho
23rd May 2011, 01:57
Paul,
Thanks for the kind words. After a hundred miles this weekend, it is just about exactly what I was hoping it would be. Everything works, no drips, mechanical or electrical issues.

I still need to trade for a regular front suspension, and I hope to find someone that wants to lower their rubbermount with my "L" parts. When that is done, then it can wear its bikini.

Thanks for your support. Your Sportster is amazing looking, and I will never get there, but I am having fun.

kr

freeidaho
5th June 2011, 02:52
Howdy,
Some progress today. Found a set of regular length front forks for my Sportster and they are on the way to my house. So after getting inspiration from AlanK in this thread http://xlforum.net/vbportal/forums/showthread.php?t=1141559 I decided to lower my front fender today so it won't hit the fairing at full bump. Besides it looks great when the fender is close to the tire.

Shoei FM2 fairing temporarily mocked up my Sportster.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0121.JPG

First step is to remove the rivets so the fender bracket and fender can be separated.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0152.JPG

Cut the fender bracket with an angle grinder and a cut off wheel.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0154.JPG

Tac-Welding the shorter brackets to the fender.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0157.JPG

Test fit of the tac-welded fender.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0158.JPG

Finish welded the brackets and filled the rivet holes. Beginning to finish it for paint.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0160.JPG

I hope to do the paint myself, so we will see how that turns out. More later.

Ken Reed

sportsterpaul
5th June 2011, 04:58
Nice work, I cheated on my fender mod, just drilled the mount holes higher up. Course I still didn't like the way the stock fender flaired out on the back and up on the front so I went with the sport fender when I added the V-Rod rear fender. Still may have to pick-up that fairing, liken the way it sets off the front end. It'll have to wait till after I get back from the MotoMarathon in New Hampshire this week.

freeidaho
5th June 2011, 05:13
Paul,
Thank you. Where can I see more pictures of your Sportster?

When I read your reply, I realized I had one more picture to post. I added a pix of the test fit above.

Ken Reed

freeidaho
1st August 2011, 01:44
Howdy,

A bit of progress on mounting some quick disconnect saddlebags. I have never cared for the little bolt stubs sticking out on quick detach bags, so I drilled out and tapped four of the mounting holes on the rear fender struts to 1/2-13. The bolt holes will be empty when the bags are off, or maybe they will get little black plugs if I can find the right thing.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0206.JPG
http://www.parmarng.org/freeidaho/MiscHost/IMG_0208.JPG

This is two pictures of the mock up of the bags to mark the locating holes.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0209.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0210.jpg

I still have to build the mounts, and that comes next. These bags have shock cutouts and sit very close to the frame, which I like.

Ken Reed

wedge
1st August 2011, 03:42
Paul,
Thank you. Where can I see more pictures of your Sportster?

When I read your reply, I realized I had one more picture to post. I added a pix of the test fit above.

Ken Reed
That's a darn nice looking fender. How did you get the arc right? That is the only sporty fender that I have seen that matches up to the 19" wheel. Good job, and you are right it does look better close to the tire. Just be careful if you ever get on wet clay, because it will build on the tire and lock the front wheel like you locked up the brake. Not something you are likely to do on purpose, but it builds up fast, like before you have time to think that it could be a problem. Just sayin... because I got a face full of dirt a few times (slow learner). Even after the first time I was foolish enough to think it was an isolated incident.

freeidaho
1st August 2011, 03:46
Wedge,
The best I can say is that I hand formed the fender over my knee and kept checking it against the tire. After the rivets on the bracket are removed and the bracket removed, it is easy to form the fender.

Thank you for the kind words.

Ken Reed

sportsterpaul
1st August 2011, 04:46
Ken: Now that's the way the MoCo should have made the fender fit!!! It's something that has always irritated me to no end. One of the priciple reasons I added the Sport front fender. Plus I wanted a little "lighter" look with painted lowers and darkening the trees and adding gaiters. There are some more shots in my Gallery, probably should post a build thread, started to but really need to set something up in "Photobucket"? Have you gotten much running in with the Shoie M2? My riding has slowed down some with the record heat here. Hottest July on record. Don't mind running at night and with the critter activity in helps sharpen the reaction tomes, always a good thing. Just waiting for the new rear belt, front and rear sprockets, and rear master cylinder rebuild kit. Should hit 90,000 this month.

freeidaho
1st August 2011, 04:52
Paul,
It is always good to hear from you. The standard height front suspension has to go on before the Shoei. That is next, or at least in parallel with the bags

It is hot here too with some days over 100, and I always wear the dork jacket (hi-viz), chaps, helmet and gloves. The ride out in the morning isn't bad but afternoons are very hot.

I will check out the gallery cause that is one nice looking Sportster you have there.

Ken Reed

sportsterpaul
1st August 2011, 05:33
I didn't realize there was a clearance issue with the fairing and the front end. You started with a "Low"?

freeidaho
1st August 2011, 15:44
Paul,
Yep, it was a low, soon to be standard height in the front. The rear already got longer shocks.

The height of the fairing is dictated by the height of the handlebars, so everything adjusts from there.

Thank you,

Ken Reed

wedge
1st August 2011, 21:04
Ken: Now that's the way the MoCo should have made the fender fit!!! It's something that has always irritated me to no end. One of the priciple reasons I added the Sport front fender. Plus I wanted a little "lighter" look with painted lowers and darkening the trees and adding gaiters. There are some more shots in my Gallery, probably should post a build thread, started to but really need to set something up in "Photobucket"? Have you gotten much running in with the Shoie M2? My riding has slowed down some with the record heat here. Hottest July on record. Don't mind running at night and with the critter activity in helps sharpen the reaction tomes, always a good thing. Just waiting for the new rear belt, front and rear sprockets, and rear master cylinder rebuild kit. Should hit 90,000 this month.
Yeah, +1, and hi-5. That's one of the main reasons I do not run a front fender. Along with the dent that some jack wad put in it by doing a burn out in 2 - 3" rock because he was pissed that the archery club was closed for maintenance. And along with I hate front fenders anyway.

But if I ever want to run a fender, this is exactly how I will do it.

freidaho When you bend it over your knee (sounds kinky), does it flare out wider any amount that is worth mentioning, and if so how did you control it?

freeidaho
1st August 2011, 22:20
Howdy,
First let me say that I learned how to do this front fender thing right here on the XLForum, in this thread http://xlforum.net/vbportal/forums/showthread.php?t=1141559&highlight=fender+recurve

That is where the credit goes.

Yes the fender gets an 1/8" wider or so, but I didn't control it, and it did not matter. I cut the bracket apart anyway, so width didn't matter. The fender mounts up fine, so the width didn't make a difference.

Thank you,

Ken Reed

freeidaho
6th August 2011, 22:09
Howdy,
A bit of progress today.

Ever wonder how much difference there is between the regular front suspension and the one on the Low models?

http://www.parmarng.org/freeidaho/MiscHost/IMG_0216.jpg
http://www.parmarng.org/freeidaho/MiscHost/IMG_0217.jpg

Ken Reed
ps: the low front forks are for sale, 2006, 3400 miles.

beornj
6th August 2011, 23:15
FreeID, where did you get the standard length forks? I've been wanting to ditch my hugger front end for a while now. Did you get that local or order it? And while I'm here, I have to say nice build. We should really meet up and ride someday. I bet you don't live ten miles from me.

freeidaho
6th August 2011, 23:30
Beornj,
I bought the front forks from a seller on Ebay, new in the box, for a great price. Then I spent a few hours preparing them for paint, and finally painting them.

It was an estate sale item that made it to EBay. They guy had the original HD boxes.

When I'm looking for something I just set up a search that automatically emails me a list of items I am looking for every day. Sometimes it takes several searches using different words or in some cases misspelled words to find something.

It took from about October of last year to about April for me to find these forks at a price and condition that I liked. I must have looked a several hundred Ebay ads. I have bought the bikini fairing, front forks, headlight nacelle, tail light, rear fender wiring harness, a normal length jiffy stand to go with the normal length suspension, a LePera seat, handlebars from a Custom, extended shaft rear view mirrors, K&N air filter, etc. It has been a good avenue for me, but it takes patience.

Thanks for the kind words.

Isn't amazing how many Sportsters are in out area, and I think there are only three of us that read/post here.

Take care,

Ken Reed

sportsterpaul
7th August 2011, 04:10
Ken: I also favor painted lower legs on my bikes, both the 2000 C, and 2006 R have them. It brings the front ends back into the overall scheme of the bike for me. Also makes it easy to find in a crowd!

freeidaho
7th August 2011, 04:43
Paul,
Agreed.

I rode behind the Shoei today. Hands, arms, chest and neck are protected. Wind does hit the helmet at the chin.

Ran into one thing I should have anticipated. The hardware for mounting the upper mounts to the handlebars does not work on 1" bars. I will need to make something. But it is secure enough for now without them.

More pictures tomorrow.

Take care,

Ken Reed

sportsterpaul
7th August 2011, 17:37
I dropped my small windscreen off back in May, have been running the bike naked, including the MotoMarathon over in New England- 3100 miles in six days, and it works surprisingly well for this old guy. But I know come winter I'll be behind something! It's all good when you can get out on the open road!

freeidaho
13th August 2011, 21:34
Howdy,
Another update. The detachable brackets are ready for the metal brake. Here is a shot of the pre-bent bracket. Note the bend line down near the rear pulley. That square piece of metal below that will be bent horizontal and the bag will sit on it. The holes around the periphery are to allow pop-riveting the bag to the bracket.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0220.jpg

Ken Reed

freeidaho
19th August 2011, 01:25
Howdy,
I have been following the thread about the Scavenger oil change system, and I like the idea of getting all the old oil out of the engine and lines during a change.

So I bought the remote oil filter from Jegs as suggested, which is a Derale Performance Engine Spin-On Adapter Kit from LA in Kali. It is made in the USA.

In order to minimize the amount of oil the "puck" will hold I drilled it and tapped it as shown. Now the oil comes into the puck and goes back out immediately.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0222.jpg

This eliminates the short hose I have seen used in other homemade pucks.

Ken Reed

sportsterpaul
19th August 2011, 02:52
Just curious, but with my JAGG oil filter adapter installed behind the filter, I'm looking at two oil lines running to the cooler. Are you following me so far? one must push from the pump, correct? Why can't I scavenge with that lineas well?

freeidaho
19th August 2011, 03:00
Paul,
I haven't finished the research on the Scavenger, so I am not an expert on which way the oil flows. I think I read that Evo motors push oil from the sump to the filter and to the tank, but I'm not sure. If this is the direction of flow, your idea works.

I'm going to go back and re-read and take some notes on the Scavenger thread to understand what else I need to fabricate.

Sorry, no help,

Ken Reed

freeidaho
20th November 2011, 03:46
Howdy,
Here is a sound byte of my Gronk mod mufflers with a 5/8" hole drilled into each baffle. To my sensibilities this is the perfect sound. I can start it in the morning without t-ing off the neighbors. It sings to me when into the throttle. It makes an absolutely excellent sound when letting off the throttle between gears. Shift at 2500, mellow but definitely a V-Twin. Shift at 3500, it barks a bit. Shift over 4000 and it really talks to me.

http://www.parmarng.org/freeidaho/MiscHost/Gronk++Baffle.675_sm.wmv

Ken Reed
__________

freeidaho
10th January 2012, 22:17
Howdy,
I haven't been working on the Sportster for a while because I have been making a new tool for my shop. It is a 2" x 72" belt grinder.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0187.jpg

You Tube: http://youtu.be/56lDDNqWhQc
Plans and Pictures: http://www.parmarng.org/freeidaho

Hope this helps someone else,

Ken Reed

beano
10th January 2012, 22:33
sweet my man...b.

freeidaho
11th January 2012, 02:19
Thank you Sir.

kr

gypdawg
11th January 2012, 04:43
nice work freeidaho, way to step outside the box and use your imagination to fabricate things. Im liking the seat lock,great idea!

sportsterpaul
11th January 2012, 05:12
Ken: Kudos to you, I just browsed you list of creations. Impressive.

freeidaho
11th January 2012, 05:15
GypDawg, Paul,
Thank you Sirs. Hopefully I can use this monster on a Sportster project soon.

Be Safe, Gas it up, Wheelie if you got it.... repeat.

Ken Reed

grampadac
11th January 2012, 08:38
That's nice.

freeidaho
11th January 2012, 14:42
Thank you Dac,

kr

MaNickles
11th January 2012, 14:53
Looking great the choke knob was the thing i ever did as well.

freeidaho
11th January 2012, 18:44
MaNickles,
Thank you!

kr

freeidaho
6th May 2012, 23:34
Howdy,
Finally finished my bags, and it took way too long. It was a whole lot of work, but they are very easy and quick to remove or put back on.

The mount and support for the leather bag.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0214-2.JPG

View from the front.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0249.JPG

View from the side.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0248.JPG

View from the back.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0246.JPG

It took me 32 seconds to go from this to a fully installed bag.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0252.JPG

Ken Reed

sportsterpaul
7th May 2012, 00:57
Ken: Nicely done again, should be able to haul more than a few rounds in them there bags!

freeidaho
7th May 2012, 01:46
Paul,
You are always so kind. Thank you,

Ken Reed

freeidaho
19th May 2012, 04:03
Howdy,
No pictures this time, but I just began the long wait for a D&D Bobcat to show up.

Hot Damn ! ! !

Ken Reed

MacSporty02
24th June 2012, 07:37
Nice transformation KR... I like it!!

freeidaho
24th June 2012, 17:41
Mac,
Thank you Sir. Got the Bobcat and I'm going to do the Bobcat and Krankenvent together when I get some time.

Be safe, have fun, wheelie if you can!

Ken Reed

freeidaho
8th July 2012, 21:15
Howdy,
Just added a GPS to my toys list, and needed 12 volt power for it on the Sportster. Looked high and low and did not find anything to my liking. Lots of handlebar mounts, but none that fit the style of my motorcycle.

So here is what I made. Hope it helps someone.

Ken Reed

Layout on 16 gauge mild steel.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0342.JPG

Screwed down to 2x4 to drill 1-1/8" hole with stepped drill.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0343.JPG

The power outlet and mount.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0345.JPG

All mounted up, ready to go.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0359.JPG

freeidaho
29th July 2012, 03:09
Howdy,
The GPS is "mounted" and working great. In town I can hear the Garmin calling out the streets and turns. The touch screen works great through the clear plastic map pocket.

The prototype mount is three layers of cardboard glued together and painted black. If this turns out to work over the long haul, I will reproduce the mount in kydex.

I chose this method of mounting the GPS because it is fairly waterproof, isolates the unit from vibration, and it comes into a restaurant with me when I stop, and I only use it when the tank bag would be on the bike anyway.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0396.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0407.JPG

Ken Reed

Rico 05R
29th July 2012, 06:15
Well done dude...have some rep.

freeidaho
29th July 2012, 18:38
Thank you Sir ! ! !

sportsterpaul
29th July 2012, 21:44
Nicely done Ken, what model did you get and what was your criteria?

freeidaho
29th July 2012, 22:37
Paul,
Thank you !

I bought the Garmin 1490LMT. I wanted something with a 5" screen and lifetime maps. Garmin is the only brand I really looked at due to prior experience and history. I wanted a dedicated GPS instead of a phone, because if you live in the boonies like I do, when phone service is unavailable, so is the GPS in a phone. In much of Montana, Wyoming, Idaho, Utah and Nevada you can go for a hundred miles or more without a phone signal.

It works in the truck too.

Ken Reed

awol70
8th August 2012, 16:21
stellar thread,ken. (I envy your skills..)

freeidaho
9th August 2012, 00:34
AWOL,
Thank you Sir !

Ken Reed

freeidaho
3rd September 2012, 03:10
Howdy,
Thank goodness for long weekends, I finally got to doing my crankcase vent project.

First, a big thank you goes to Deimus for documenting his search for better crankcase ventilation. Thus I am doing his Krankenvent modification.

Here is the bike torn down, ready for the cam cover modification.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0445.JPG

Beginning fabrication of the oil control baffle.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0446.JPG

The baffle, final form.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0447.JPG

The baffle installed.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0448.JPG

Tapping the cam cover for the vent fitting.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0449.JPG

Making sure the cams are still in time. Some of them came out with the case.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0450.JPG

Tomorrow, I will finish up putting back on the tank, and putting on the Bobcat. But this is enough for today.

Thanks for checking by,

Ken Reed

sportsterpaul
3rd September 2012, 05:21
Ken: Nicely done, unlike me who is dealing with a seized oil pump. Less than 3,000 miles on the rebuild, and this is supposed to be the latest and greatest pump. I'm hoping that it hasn't destroyed $3,500.00 of new parts, expecting some word from H.D. Tuesday, wish me luck.

freeidaho
3rd September 2012, 06:00
Paul,
Ohhhh, that makes my heart hurt. I am truly sorry. I will keep a good thought.

I wonder if the pump swallowed something?

My best to you,

Ken Reed

sportsterpaul
3rd September 2012, 06:37
Aaron posted back that his experience has shown ingested parts of a piston or chips off a gear would be suspect. Will need to do some more tear down.

CBryant
3rd September 2012, 18:10
Just found this thread and read the whole thing. You do nice work! Thanks for sharing. I especially like the mod to the fender brackets to receive bags. Mine are solid mount harley bags with cutouts in back for shocks. If I want to remove them it will take an hour minimum. Woohoo, grade 8 bolts and a tap! I'm stoked. Also, the photo of the front forks showing low and standard lengths was very enlightening. Thanks

freeidaho
3rd September 2012, 18:20
CBryant,
Thank you Sir.

There are so many generous people that help on this forum, it is hard to be useful here. I glad you got something out of my work in progress.

Now that I have the crankcase vented properly I can finish my air cleaner too.

But today I'm working on the D&D Bobcat install. Pictures later today.

Thanks again,

Ken Reed

freeidaho
4th September 2012, 00:16
Howdy,
Finished the crankcase vent.

This is the fitting that screws into the cam cover that provides the vent.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0451.JPG

This is the Kranken Vent up near the steering head. The long run of tubing with the valve at the top should help seperate air from oil mist.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0452.JPG

Next the D&D Bobcat went on. First thing was to round one corner of one of the brackets. It was a sharp corner that could touch the belt. I actually rounded both corners after this photo was taken.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0453.JPG

The D&D Bobcat instructions do not come with pictures or diagrams. This is where the "L" shaped bracket goes. The other bolt is from the sprocket cover. This bracket holds up the end of the header.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0454.JPG

This is the other bracket shown close to the correct position. Of course it comes away from the belt in the final use. This bracket holds up the muffler.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0455.JPG

Here is the finished result. The Sportster sounds like a big dog now, and I love it. The shape of the headers are what attracted me to the Bobcat. I like the pair of pipes going down behind the brake lever.

As others have said, this exhaust is first class craftmanship, and the fit is excellent.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0456.JPG

Ken Reed

freeidaho
10th September 2012, 02:09
Howdy,
It is sure is nice that my Sportster does not slobber all over itself anymore.

I will still add a length of hose to the output side of the Kranken Vent but it is not needed.

Thank you Deimus ! ! !

Plus the looks and the sound of the D&D Bobcat are excellent. Nice tone, decent noise level but not over the top. And if you are really making tracks it talks a race car talk.

Ken Reed

Hands0fDeath
10th September 2012, 03:12
Awesome documentation on a great build-up freeidaho! You do some quality work. Rep to you!

freeidaho
10th September 2012, 04:14
Hands,
Thank you Sir. It is one of the great pleasures in my life. So many great posters here, that I have learned a ton about my Sportster in the last two years.

Thanks again,

Ken Reed

rippin-j
16th January 2013, 01:47
Fantastic thread. Thanks for the great ideas but more so for the simple and detailed documentation. Been talking about building some quick disconnect bags and the custom fab ideas are also very tempting. Thanks for posting! When you have time send a clip of the new exhaust sound.

freeidaho
16th January 2013, 01:54
Rippin,
Thank you Sir for the kind words.

It will be a while for the exhaust clip but I'd like to do one. We have quite a bit of snow on the ground with daytime highs of about 20 degrees.

Thanks again,

kr

sportsterpaul
16th January 2013, 03:19
Ken, Yep that "Bobcat" is one great looking pipe, and suits your ride well. Wouldn't mind trying one on mine just not in the cards at this time. Enjoy your ride my friend, regards Paul.

freeidaho
16th January 2013, 03:57
Paul,
Thank you Sir. Funny you should say that since you have one of the best looking Sportsters I know of. I wish mine weren't Black, but it was the Craig's list luck of the draw.

Take care,

kr

sportsterpaul
16th January 2013, 04:10
Ken, Ol' Orange is looking "rode hard and put away wet" which she is after chasing some forum members around lower Ontario almost 300 miles last Saturday! There is a rumor that the black ones are the fastest, but again that's just a rumor. I do feel the ned to add that for my taste it's awful hard to beat the look of black and chrome! Regards, Paul.

freeidaho
25th April 2013, 01:45
Howdy,
Life has been getting in the way but I made a teeny bit of progress today. Finally found, bought and mounted a clock. It is a Formotion ELA-20720 Electro Luminescent Series Black Face Clock and I bought it at Amazon. I can see it with my tank bag on, and it is big enough to read at speed in the rain or whatever. It has a backlight button right on top too.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0639.JPG

It is mounted to bottom of the left mirror stud with a small bracket I made to tuck it in close.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0640.JPG

Ken

sportsterpaul
25th April 2013, 04:31
Again, another nicely done mod, kudos.

freeidaho
26th April 2013, 01:33
Thank you Paul,

kr

TheAnimal
5th May 2013, 21:19
Brilliant work, Sir!

wedge
5th May 2013, 22:40
Way cool, I really don't like digital, and that is just perfect.

freeidaho
5th May 2013, 23:15
Animal and Wedge,
Thank you for the kind words. As you know, it is a labor of love.

kr

freeidaho
16th May 2013, 06:07
Howdy,
Well this isn't exactly an update to the Sportster, but I'm pretty excited.

It is the Titan 1500XLT. Goes from 9" to 45" with 1500lbs. Has casters so you can even roll it with a load.

I plan on putting a 1/2" thick steel plate on the top, and make it a better hydraulic welding table, mechanics table, and still a motorcycle lift.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0651.JPG

kr

Scar55
16th May 2013, 12:18
Nice build. How about some pics of your machine shop. Are you doing the work in a real machine shop or do you have a garage shop?

Kelly

freeidaho
22nd June 2013, 22:52
Starting a new project. Need a quick on/off luggage rack with quick on/off sissy bar for longer trips.

First step is to prototype up some possibilities. Cardboard is your friend.

Try One
http://www.parmarng.org/freeidaho/MiscHost/IMG_0688.JPG

But I am tending toward this one.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0691.JPG

One might ask, "Why make one?" I can get exactly what I want. And I will probably have $20 in materials when done.

kr

freeidaho
23rd June 2013, 04:00
A bit more progress.

Bending the perimeter piece.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0681.JPG

Beginning of the inner pieces.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0692.JPG

A pattern cut from 3/8" plywood and smoothed. Smoothing the edges is the key to smooth plasma cutting.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0696.JPG

Two side plates, ready for final forming and smoothing.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0698.JPG

Welding on the side plates.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0699.JPG

Still need to drill holes and weld on some blind nuts for a sissy bar, and drill holes for bungee cords, but done for today.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0701.JPG

kr

sportsterpaul
23rd June 2013, 05:02
Ken, you continue to amaze, nicely done.

freeidaho
23rd June 2013, 05:12
Paul,
You are always so kind. Thank you,

kr

freeidaho
19th July 2013, 17:26
Just got my custom luggage rack back from the powder coater.

Total cost $7 for steel
$30 for powder coat

Perfect size, style, and fit. Priceless

http://www.parmarng.org/freeidaho/MiscHost/IMG_0713.jpg

I should get it installed this weekend.

kr

freeidaho
21st July 2013, 05:22
Not strictly Sportster project related, but I just finished up my MIG/TIG/Plasma cart. Well not quite, I still have to weld up the drawer.

This stacked cart works well in my teeny work space. It has 30 feet of 220v cord built in, three 220v outlets, one per level, and one 120V outlet. It has big caster wheels and rolls like a dream even loaded up. There are four cable holders, and of course a 18" x 22" drawer.

The heaviest item right now is the TIG welder. It is an older design, with an actual copper transformers inside.


http://www.parmarng.org/freeidaho/MiscHost/IMG_0716.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0717.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0718.JPG

kr

sportsterpaul
21st July 2013, 14:07
O.M.G. look how clean the floor is, now I've got to go out and start cleaning mine, been shamed!

redi2ride
21st July 2013, 14:41
Very clean professional jobs u do.

Sent from my LG-LW770 using Tapatalk 2

freeidaho
21st July 2013, 20:20
Thanks guys,

Right now I have a Honda z50 on the lift, trying to recover it from the grave caused by neglect and hard use. If I can make it start, run, and be reliable, the three little boys of my friend and IDPA match director will be in mini-bike heaven.

Then I can put the luggage rack on the Sportster, and start working on new moving targets for my shooting club.

Its 103 in the shade and at least as hot in the garage, but free time doesn't hinge on the heat.

Be safe, have fun, wheelie if you got em.... repeat!

kr

freeidaho
24th July 2013, 23:11
Finally, after the powder scooter lost my rack for a couple weeks, it is on the scooter. It takes about 5 minutes to put it on or take it off, including taking off the bags.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0729.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0733.JPG

kr

yzrmbsg
25th July 2013, 00:48
Just found your thread! Very nice work you do! I wish I had the skills/tools to do that kind of stuff! I do a lot of wrenching, but I'm only 25....I have plenty of time to learn and buy more tools! I just got an 08 Xl1200N about 2 months ago! Not my first bike, but my first Harley! Anyways...I live in Kuna, so if any of you fellow Idaho sportster riders wanna meat up and go for a ride, let me know!

freeidaho
25th July 2013, 00:59
Thank you!

Be sure to put a pin in the XLForum riders map.

http://www.zeemaps.com/map?group=204484

kr

yzrmbsg
25th July 2013, 01:06
I think I pinned it...but not sure on my phone.

freeidaho
2nd September 2013, 20:12
Howdy,
Riding today. Overcast, a drop or two of rain, and pure sanctuary.

http://www.parmarng.org/freeidaho/MiscHost/IMG_0827.JPG

kr

the48'ster
13th June 2014, 03:21
Howdy. Great write up. Subscribed!!

the48'ster
20th June 2014, 02:57
Howdy,
A bit more progress. I bought a Lepera Sorrento seat. After paying nearly $400, and reading here and there about seat thefts, I started worrying about a $400 bill available to anyone with a Leatherman or 7/16" wrench in their pocket.

I asked about this here on the XLForum and learned that some people are using security bolts. After weighing that, I went another way.
http://www.parmarng.org/freeidaho/MiscHost/IMG_0049.JPG

Here are the fabrication pictures
http://www.parmarng.org/freeidaho/MiscHost/IMG_0038.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0040.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0043.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0044.JPG

http://www.parmarng.org/freeidaho/MiscHost/IMG_0053.JPG

kr


I really like this idea. Do you have more picture about how you fitted it on the fender part. Did you have to cut the fender to accommodate the lock tab to fit.?
thanks

freeidaho
27th June 2014, 23:32
I love this forum. Thanks to everyone that keeps it running and keeps it interesting and informative.

I just saw a motorcycle stopped in a line of cars get rear-ended. The rider was not hurt, but the motorcycle needed a new rear fender at a minimum.

One thing I have always envied of the barcalounger type motorcycles is the amazing brightness of their stop lights.

So in trying to create more light back there on my Sportster, I have come up with this simple and cheap solution.

I'm going to use the turn signal bulbs in the rear as additional stop lights. As so.

http://www.parmarng.org/freeidaho/MiscHost/MoreBrakeLightsSketchV1.jpg

kr