Offset pulley?

After a little measuring it seems that I will need a 1" offset 27 tooth pulley.

I've sent out a few emails to some pulley manufacturers in the states. Hopefully it won't be too expensive, as I don't think I can space out my current pulley. P&D might have some ideas when I drop it off to have the exhaust bracket moved. In the mean time I will trawl the web for pulley quotes.

Get in there you belter!

I have got the 139 Dyna belt on! Which is a right result as you cannot get custom length drive belts, or at least I can't find anywhere to do them, and no shops or builders know of any place and they have been doing this game for far longer than me. 

After taking the sidewall off my rear pulley and wrestling with the belt for a bit, I squeezed it on there and now all seems fine regarding belt length.

The front pulley will need to be spaced out though, as the belt is not sitting straight. Also as the wheel is in at its minimum adjustment position the rear mud guard bracket will probably need tweaking to give the wheel some more space. 

I'm hoping the lads at P&D can modify my transmission pulley, perhaps counterbore the fixing holes or work some magic to keep the thread engagement the same while moving it, otherwise I will need to purchase an offset pulley. But I've not found any 27 teeth ones. If I go any higher on teeth the belt won't fit.

Once this is sorted I can concentrate on getting the brake controls set up and get the frame powder coated. I need some new brake levers too. The cheap ones I currently have look pants and will probably fall apart when i use them. More Ebay'ing.... It's becoming expensive.....who am I kidding....becoming!! It's already cost me a fortune!  I keep telling myself it will be worth it though.

Belting pain in the ass!

I measured my new required belt length, and calculated the teeth quantity of the belt. (Divide belt length by 14mm for those interested).

I calculated it to be 140 minimum, however I spied a 139 tooth belt from a dyna for £30, so took a gamble as it was a standard size.

Yup... It's too short. So I'm now trawling the web for a custom belt manufacturer. I will go 142 teeth to be on the safe side after offering up the 139.

I need to throw the old sportster and the Dyna punt belt on Ebay.

It's also looking like I will need a spacer on the drive pulley. I'm due to have P&D look at it in a few weeks.

I've sourced a new rear numberplate holder, cheap as chips from China, but I'm chuffed with the quality and the look. Will need to tweak it a little to fit though.

The exhaust bracket might be a little close for comfort, will see how it sits when I get correct belt. Also my rear brake reservoir sits on the front pulley cover.

Once the belt and pulley are properly spaced I may need to machine the cover slightly to get it to fit.

So....the belt is holding me up at the moment. Once belt, pulley and cover are sorted I can reassemble rear brake assembly. Make sure all is peachy and then dismantle to get the frame powder coated. pics will follow..... Right! back online to find custom belt suppliers.