Get the beers in!!

What an afternoon! But first a little catchup.

The tins are out to paint. I've decided a metallic blue base colour with cream panels, a silver pin-stripe will separate the two colours.

Currently I've not bothered sending the front mudguard to paint as I like the look without and I've not got round to shaping it and cutting it down to size. Perhaps I'll get it painted later.... We'll see.

I can't start it until the oil system is complete. So once the oil tank is back from paint, I'll connect it up, fill it with oil and all systems are go.

So, back to this afternoon, with the tanks and mudguard due back at the end of the month, it's time to start the wiring.

I've deciphered the wiring instructions that were for another unit, with incorrect colour codes and after a bit of head scratching.... I've got the starter motor to turn over.

This may not sound ground breaking, but it's definitely beer worthy. It proves the starter system works as it was 2nd hand and unused. In theory I could start the bike now. All breakers are working and diagnostic led's are working like they should.

I've ordered a super lightweight and more importantly smaller than normal size lithium battery which is still in the post.

In the meantime I'm using the battery from my quad-bike for wiring.

So with the engine ready to fire it is time for a beer!

Sadly I only have one beer left in the fridge......

It's been in there for months after the misses picked some up in the summer.

I'm not a big fruit beer fan, but with standard beer stocks run dry during World Cup rugby time..... Needs must.

....... It's not too bad actually! I wouldn't go out and buy anymore though.....but it's done the job.... I'm very happy to toast today's progress..... Cheers!!

Getting it together.

An eventful few days, I've juggled working on the bike with watching the World Cup rugby. All things considered....it's coming along nicely.

Bars are on, throttle cables and carb are assembled along with the electronic module has been fitted after I cobbled together a bracket. No wiring done yet though.

I painted the ignition coil bracket with some of the crinkle paint as it was looking a bit tired.

I also sprayed the voltage regulator with some matt black paint. As the original paint had flaked off.

New plugs are in. Next is to install the coil and voltage regulator. Find somewhere out of the way to put the ignition module and then run the oil lines.

Still plenty to do but she's really coming together now and I wouldn't change a thing I've done. 

She is becoming a thing of beauty!

Engines in!

The engines in. With minimal swearing, no grazed knuckles and only superficial scratches to the paint on the engine. The frame came out unscathed.

Thanks to my bro and my wife for being extra hands when I needed them!

Wheels, rear brake calliper and forks are on, and the paint on the engine has been touched-up.

I've ordered some new throttle cables as the old ones are shot. The Carb & hyper-charger is back on the engine too.

A good days work...Happy days!

Patience and face-fulls of swarf.

The paint dried well. The last couple of weeks I've been sanding back the fins with a dremel and by hand. It's taken a while but I really like the effect.

There are a few small areas to touch up with paint, but I'll do that when the engines in the frame, as there may be a few more scratches to come during fitting.

Overall though I'm very happy with the finish. It's come out better than I thought it would!

Also..... Look what else I picked up today. Smiles all round! It looks great!

He who dares... Paints?!

Well I went for it and painted the engine.

Photo of it while wet.

I blasted It with the heat gun and a portable fire for about an hour. It doesn't look too bad, however it's dark outside so I can't tell what it will look like under natural light.

It may need some extra paint in places....

Additional touch ups next and then I'll sand the fins back to ally. I've got a few weeks until the frame arrives and I wrestle to get it back in the frame.... I'll learn some new swear words in preparation for the task!

Prepping engine for paint.

With the frame out for powder coat, today I prepped the engine for painting.

3 coats in alternating directions, allowing 5 minutes between each coating. Then a blast with the heat gun is my approach. 

However, I'm going to practice with the top engine mount first.

Before:

During:

It says on the can to give it a heavy coating, there are a couple of paint runs on it due to the quantity of paint. Currently waiting for last coat to have its 5 mins drying before blasting with the heat gun.

After:

During heating the paint blistered in one area, so I tried popping it with a cable tie. Won't do that again. Overall though I like the finish so onwards to the engine.

I'll go easier with the heat next  time.

Final weld prep.

Happy with the belt guard. It's fits well and just clears the exhaust. I wrestled with the engine to get it out of the frame again. Took off the rocker covers in the end and pulled the frame clear. Will remove the covers for install too as space is so tight. 

Frame is all set for final welding. 

Tap arrived in post, pulley is now tapped to suit the cover fixings.

Looking forward to seeing the frame when it's coated.

Just waiting

I've stripped the bike down, preparing for some last welding on the bottom of the frame. However I'm currently waiting for delivery of a pulley guard.

Below is a screenshot from the guard manufacturers site.

I just need to ensure it doesn't clash with the pipes. Then the bike is off to P&D for the final welding. I don't have a pulley tightening tool, so I'll get them to drill and tap the pulley to seat the guard.

Then it's time for the frame to go to powder coat, which will be a major turning point in the build. I will paint and detail the engine. The guard is on its way from the states.... All this sitting around waiting is pretty frustrating.

Aligned and belted up!

Well it's back from my welding buddies at P&D. The pulley require a little tweaking  on their machines, but now all is good in the world.

Thankfully the belt fits. The rear axle cutouts were lengthened a tiny bit and no additional mods were required to the frame, so I got lucky there. My maths worked out and the belt I got did the business, so I'm chuffed about that.

The rear brake reservoir which was on the pulley cover is now relocated upon a small bracket on the frame which looks great. 

The original idea of spacing the pulley cover out was scrapped, basically as it looked completely crap. It stepped out too far and looked blocky. 

A new foot brake control arm to meet the reservoire has been knocked up, and although it's something pretty simple, it really does look the mutts love spuds! 

Headlight is now mounted. After receiving the wrong bracket from a supplier from the states, they kindly sent me a free replacement... Still the wrong one though, I guess it's the thought that counts though eh? I may use it elsewhere, it's currently filed in the 'random shite box' which seems to be filling up quite nicely, with old bolts and the original loom.

Anyways here she is. 

All looking good! I shall space the rear fender to be closer to the wheel, also the fender brackets haven't been assembled.

Here's the control arm. I will look into a belt cover for the pulley, I'm hoping a small plate can be screwed to the pulley just to offer a lip to the belt for safety. I'll come up with something.

The oil tank was scalloped by the P&D gurus. There really is no where to move the tank to, so this mod was the only option. I really like what they've done.

Very chuffed with the latest progress on the build. Next is to strip the bike down back to a bare frame so I can get it powder coated black.

There is some minor additional welding to be done which will be far easier to do on the empty frame. While the frame is out for paint, I shall paint the engine, and source some pipe for routing between the reservoire and rear calliper. I'm thinking black coloured solid pipe might look nicer than braided flexi-pipe. I'll see what the web has to offer.

She's getting there though and looking mighty fine!

'Pulling' forward with the build

Offset pulley arrived and it's a thing of beauty. (If pulleys are your thing) the bikes  gone back to P&D for some welding and reworking to the wheel/pulley spacing. I will post photos and full write up when I get it back....watch this space folks....

Pulley problems, one step closer

After weeks of searching for a 1" offset 27 tooth pulley, The closest I've found is a 19mm offset 27t or a 1" offset 28t

I'm worried the 19mm won't be enough. 

I got a quote to have a pulley made. 

£430 plus postage from the states. So I've decided to go for the 28 tooth pulley which set me back £105 including postage from the states.

Now I need to move the rear wheel forward by 8mm, as the belt isn't long enough. Thankfully there is enough material on the tabs of the frame. So these will be widened, hopefully with the engine still in if possible!

The rear fender will need moving forward to clear the tyre.

It's slow progress, but it's progress.

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.

Yeah I know... It's been a while

Hey folks.

Well....it's been christmas.... Yeah lame excuse but been busy with work, house and family stuff. But I'm back! 

So... Last week I looked at the oil lines. After some internet searching I found a routing diagram. 

I need to create three new oil lines. I already have an oil line kit I bought from the states and so far I've made one line and all is well. It looks pretty cool, stainless steel and  braided, so should hopefully last a long time too. The main oil feed pipe is finished and assembled. I will post a photo later.

Focus is on the oil lines and electrics. I've just purchased off ebay a full loom kit.

Cheapest I found initially was £256 plus postage from the states. They normally retail for £350. But I stumbled across this gem and wrangled it for £120 inc. postage. During negotiations and while I was doing my best Arthur Daley impressions (Google those of you outside the UK or too young to know) Emails got crossed in the cosmos. While we were doing an outside of ebay (no sellers fee) negotiation I offered £120 at the same time he said he'd take £110 for it. Either way I was chuffed with £120 so I negotiated again after looking at the chaps others items for sale. He had some funky looking rocket shaped nuts and bolts, so I got him to throw them in the deal.

So.... Here's the pics

It's a full loom kit including a key barrel and a chromed housing to hide it all in. Previously I was looking at these:

They are the usual thing to go for. Proven and reliable. Normally around £150 from the states plus import duty. The kit I've sorted includes this kit with the machined and chromed cover and an ignition barrel and key set, so I'm chuffed to bits and have grabbed a bargain. The chap brought it and never used it. 

Once the oil lines are set and the electrics are done. I can start her up. 

One thing I noticed last week is that the  original standard drive belt is too short. The whole frame is longer now. Belts are sold by length calculated by tooth quantity in the belt.

It's 14mm from tooth to tooth, so when I have a minute I will grab some string and measure the length of belt required and grab one off the web. I'm guessing it will be a custom size.

So all is pretty peachy right now. 

Oh... Here are the rocket nuts I got in the deal.....

I don't know where or if I will use them on the bike yet.. But either way they are pretty groovy, so happy days.

Taking shape

......she's back from P&D customs.

The tank fits like a dream, I'm over the moon with the look. They had to mod the frame a little, move the seat back a smidge, but the end result is superb! 

The exhausts, although a bargain off eBay didn't fit as well as I'd hoped, however after cutting and welding a new section to each pipe (removing the old lambda ports, which is handy and looks far better than my original idea of blanking them off with some screws) they now look superb. 

The rear fender is now shaped with a pleasing rounded off bottom edge. 

The side stand has been rotated and now the bike sits at a far better and secure angle when on the stand.

Upon reflection of the bike in its current state, I've decided the brake levers have to go. They just look cheap and nasty....which they were really!

Also, now I'm not convinced on the blue flames paint job. Flames won't work.

I've bounced a few ideas around of nickel  plating the frame and tins, however with a chrome front end it would look weird and the engine will be shown up. You'd need a polished engine for that. So.... Right now the intent is for the frame to be black and the tins to be a beautiful orange colour. Metal flake, hotrod style, perhaps with some white pinstriping. A white seat with orange criss-cross stitching. This kinda shade perhaps?

Anyways, here she is as she stands!!

And a thanks to Chris from P&D for dropping her off (pictured below) and both Chris and Dave for all their help so far!

So next jobs are oil lines, electrics, and cables. Find myself some new levers, sort lights and number plate, 

Liking the no indicator / speedo look. Keeps the front end looking clean.

The build really has turned a corner. The winter months are drawing in, perfect time to get the jobs done ready for next summer.

So.....to sum things up...its simple really.... I love it and it's 'effing awesome!

I'm still here!

Its been crazy times lately. Work has been hectic, trips to America, I went to Detroit and Minnesota. 

It was my wife's and my birthdays in July so we took a week off work for days out.

Also I've been decorating the house, and fixing up the car. Rear suspension was shot and replaced the exhaust as was blowing a little and got a good deal on an aftermarket race spec exhaust. Sounds awesome! 

Anyway..... Enough car and house chat and my lame excuses for not cracking on with the bike...... 

The bike! I've had a rough quote from the  metal magicians at P&D customs for them to do the following:

1) manufacture and weld exhaust brackets.

2) weld fuel tank brackets to frame.

3) modify side stand (currently too long as bike is lower now)

4) round-off rear fender as currently too square at the bottom.

I need to phone them back this Friday to book in a time for them to transport the bike to their workshop.

Once these few small jobs are done I can concentrate on the electrics, cables & oil pipes. 

Once the tank is on I will post more photos. I'm hoping the handlebar risers are tall enough for the bars to clear the tank when turning full lock.

New exhaust - eBay win.

I have held out on having the welding done for the tank for now. As I won an exhaust on EBay. They came off a standard sportster so hopefully they will fit ok. I really like the aggressive cut at the end of the pipes.

It makes more sense to have the welding for the tank and exhaust done at the same time. As the bike will need to be transported to the P&D.

I won't need the lambda sensor ports on these new exhausts. Depending on the condition of the chrome I may just buy a chrome plug for them. Or have the ports ground off, filled and the pipes re-chromed.

So the next job is the welding. Then I plan on refurbing the forward controls from the original bike. The chrome looks a little tired. So a good cleanup and re-chrome is in order. New footpegs cost a small fortune for what they are so I'm happy to work with what I have.

Cleaning, sealing and breathing.

After a little fettling of the original upper engine mounts and the arrival of some more suitable fixings I have completed fitting the engine.

I gave the carb a good going over with degreaser and replaced all the seals. Cleaned and replaced all the gaskets on the air cleaner.

Added the additional air scoop I brought a while ago to the hypercharger. I was a little concerned it may be too wide to get my leg passed comfortably while seated, but it's fine. 

Looks pretty knarley I reckon!

I am busy trawling eBay for stylish exhausts. One has caught my eye. 2nd hand from the US.

I have spoken to P&D about welding tank brackets in place. So now the engine is in and carb etc. the tank can be properly spaced from everything.

It would make more sense to get the welding done for the exhaust brackets at the same time. So I'm hoping I will find something soon.