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  #1  
Old 22nd October 2012
DP CUSTOMS DP CUSTOMS is offline
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Default 1200 Build thread! Defensor II

You guys have probably seen a couple of our bikes here before... Jarrod and I are tearing into another! This time, an '01 1200. We'll have a few performance mods on it, like better brakes, exhaust, intake and single fire ignition. The biggest mod, of course, will be weight savings. Hope you like the build so far. We have more posts on our FB page, make sure to follow us!
http://www.facebook.com/pages/DP-Cus...17477074951026

This build will be based on our original Defensor Ironhead:


Now for the Evo ... here's where we started after stripping it down:


The frame chopped and ready for a hardtail.



Lining things up on the jig:


Mocking up the new peanut tank. We had to cut off the mounting tabs and make new ones for it to sit how we wanted.


Building a battery box and checking for fitment. Yep, she's tiny and really light.


Time for final TIG welding on the table.


Now for the front legs... time to cut and shave them. Then off to polish.



A roller! Still a mock-up but you can see where she's headed. Freshly laced wheels, Pirelli's and a rebuilt front end.


And now with the motor. We're lining things up for axle spacers, sprockets, etc.
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  #2  
Old 22nd October 2012
shotgun46's Avatar
shotgun46 shotgun46 is offline
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Looks like this is going to be good !
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  #3  
Old 22nd October 2012
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Wow, that's tight! Can't wait to see the finished bike.
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  #4  
Old 22nd October 2012
18Bravo 18Bravo is offline
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I love it!
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  #5  
Old 22nd October 2012
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geoff 1 geoff 1 is offline
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Looking good,build threads rock,& yours is looking great!
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  #6  
Old 22nd October 2012
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Is that a 18 rear and 19 front?
Looking good so far!!
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  #7  
Old 23rd October 2012
DP CUSTOMS DP CUSTOMS is offline
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@ Daytona... yep, you're right on the wheel sizes - good eye.

And now to get rid of some of the engine chrome. We're pulling most of the parts to get them powdercoated in satin black. God damn Harley has some of these parts torqued on like sonsofbitches!


Jarrod just pulled off the rocker boxes and now the primary cover:


On the bench to remove the chain tensioner, shifter seal and gasket material:


The 1200 sans primary cover and rockers:


Off with the cam cover, all looks good inside:
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  #8  
Old 23rd October 2012
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Got cams?
And since you are this far, why not do a little head work......
You know you really really want too!
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  #9  
Old 24th October 2012
DP CUSTOMS DP CUSTOMS is offline
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Quote:
Originally Posted by DaytonaSportster View Post
Got cams?
And since you are this far, why not do a little head work......
You know you really really want too!
Yes, we hear you Daytona. Unfortunately, we've got a budget to stick to. However, we're always open to horsepower donations!
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  #10  
Old 24th October 2012
DP CUSTOMS DP CUSTOMS is offline
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A big day today, parts to drop off for powdercoating and a big part to pick up.. the frame! Ain't she pretty? Feels like Christmas:



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