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  #76 (permalink)  
Old 02-10-2015, 08:52 PM
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Yes , that's the math, very good!
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2004 Ultima 127 Chopper
1975 Harley Davidson Shovel head Chopper
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  #77 (permalink)  
Old 02-27-2015, 09:49 AM
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Bike Year, Make, Engine: 1997 Buell 1203 Mutant
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Making some more progress.
not super interesting, but ran my oil lines. not sure how others are doing it on the mutants, but this is how i did it.



Vent and return come up behind cam cover and then get tucked next to and behind starter motor. keeps them out of the way of the exhaust.
feed line drops down from tank to underneath motor/on top of battery. comes over to oil pump (behind cam cover)

also have started machining some components. this is the fun stuff i thought people might like to see. but it's slow going as i'm learning how to use my lathe and mill (manual) as i go.

This is to be a foot peg. the last pic isn't finished yet, need to mill down the mount end and also going to mill some details. then powdercoat. either black or gold, not sure yet.
I really like the idea that i am making these parts, and they will be 100% unique to my bike.





Still To Do List:
-finish machining foot pegs
-machine shift/brake pegs
-machine grips
-machine hand control switch housing
-machine rear turn signals
-powdercoat machined parts
-finish wiring hand controls and turn signals
-weld gas tank mounts
-lab metal (heat safe bondo) gas tank
-powdercoat gas tank
-modify exhaust and fabricate mount
-paint exhaust
-fill fluids
-cross fingers, push the red button

Last edited by bondo167; 03-02-2015 at 09:30 AM..
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  #78 (permalink)  
Old 02-27-2015, 03:26 PM
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Looking good , good to see that you have been busy!
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2004 Ultima 127 Chopper
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  #79 (permalink)  
Old 02-27-2015, 06:53 PM
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Would be interested to know how you put that rough surface on the finished foot peg.
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  #80 (permalink)  
Old 02-28-2015, 06:20 PM
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The process is knurling. It uses a tool that has 2 wheels. One has right hand angled teeth and the other has left hand angled teeth. Together they cut the diamond shape.



Here's steps to make my shift/brake lever pegs. With some pics of the knurling process.







To knurl I first start with the desired diameter, say 1".
Then I calculate what diameter I actually need the part to be based on the knurling tool pitch - teeth per inch. In this case my tool is 20tpi. i don't remember what it came out to be, something like 0.992".
Then I turn the metal to that diameter.
Then align the knurling tool square to the piece. Push it in real tight, spin the work by hand to see if it's square and forming proper diamond pattern.
Then I set my lathe speed as low as possible, set my auto feed slow.
Then start the lathe for a couple seconds and then stop it. I check to ensure proper pattern. If it's not right, push the tool in further and try again. Once it looks good I engage the feed and turn on the lathe. Takes a couple passes each direction, pushing in maybe 0.005" each pass. I just keep checking and stop when it looks right.
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  #81 (permalink)  
Old 02-28-2015, 07:39 PM
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Super cool! My dad recently passed away and left me with a lathe and vertical mill, but I would have to tear the back wall out of his shop and have it hauled 20 miles to my house. tough job,
but I would love to try some of that kind of stuff. I had a small lathe at my last house that burned that I used to build the Shovelhead with but i was too slow getting it out and the scavengers stole that one. I think I'm going to go get his setup , I miss it. Nice work, thanks for the demo.!
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2004 Ultima 127 Chopper
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  #82 (permalink)  
Old 03-02-2015, 09:41 AM
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sorry to hear about your dad. sounds like it would be a lot of work to get the lathe and mill, but i think you should! in my opinion there's just nothing that feels quite the same as making something with your own two hands (and some tools). i've always loved building houses, sheds, decks. now getting into machining these, and it's the same rewarding feeling.
my lathe is from ~1930 i think. was collecting dust in my dad's basement after my grandfather passed in 1998. it's nice working with his old tools.
my vertical mill is a small thing that my grandfather pieced together. i believe he made some of the pieces for it on the lathe.

anyway, process on the project: finished the lathe-ing of all 4 pieces for the feet. and my rotary table/indexing head combo tool just arrived from ebay. so i'll hopefully make some more progress tonight.
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  #83 (permalink)  
Old 03-02-2015, 03:56 PM
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Nice, hurry up and finish this bike so you can start on another!!!
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  #84 (permalink)  
Old 03-03-2015, 08:11 AM
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haha, it's almost like you know me.
i was actually looking at bikes the other day, to my wife's dismay. "why do you need 3 bikes?"

anyway, i'm up in Vermont so i've got another 2 months at least before i can ride. hoping i can have this wrapped by then.
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  #85 (permalink)  
Old 05-04-2015, 10:13 AM
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I'm definitely not close to wrapping this up yet, of course. between life and my over-zealous ambitions it's no wonder this has taken 5 years so far.
anyway, finished the foot pegs and grips. the throttle-side grip was a giant pain in the ass, but i learned a lot of things i would do differently next time i machine some grips.

all lathe'd (is that a word?) on 70+ yr old Atlas lathe that was grandfathers.
milled using a small hand-made milling machine (made by my grandfather).
and a 4" rotary table/indexing head from ebay.

7 hole pattern: (required use of an indexing head)



foot pegs:


left grip:


machining throttle features: (required rotary table):


right grip done (needs some minor touch up/deburring):


big items left:
-TANK! (needs some welding, some lab-metal smoothing, powdercoating, sanding, buffing, waxing)
-Seat. need to find someone to re-shape and re-upholster it.
-Hand controls. need to fabricate (this will probably take a while, may do a work-around to get it running).

Some of the little things:
-powdercoating machined parts
-cut exhaust, paint, remount
-wire hand control switches (after housings are fabbed)
-wet sand and wax rear fender (showing too much orange peel)
-front fender?
-gas cap
-petcock/gas line
-bleed brakes, fill fluids, adjust clutch cable . . .

seriously, i do plan on having it done sometime this summer. going to take a break to get my daily rider ready to ride, and then back to it.
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  #86 (permalink)  
Old 05-04-2015, 10:16 AM
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(deleting accidental double post)

Last edited by bondo167; 05-04-2015 at 10:19 AM..
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  #87 (permalink)  
Old 05-04-2015, 11:17 AM
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LOVE the grips man. Would love a set lol
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  #88 (permalink)  
Old 06-02-2015, 09:08 AM
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Thanks Spade.

i've re-made my switch housings. i'm not in love with my new design, but i really hate the old ones (mostly because the switches were absolute junk - and i went from 3 on each side to 2 anyway). here's the finished, sandblasted part. will be powdercoated black. hope to get them on the bike and wired up in the next few days.


making these involved finding new switches, designing in CAD, finding material, lathe, bandsaw, milling machine, band saw, milling machine, hand-tap, belt sander. . . so they've taken me a while.

getting close. i'm hoping i can get it done by July.

main to-do list:
-tank mounted and powdercoated
-hand and foot controls powdercoated
-final hand control wiring
-seat reupholstered
-exhaust cut and painted and mounted.
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  #89 (permalink)  
Old 06-18-2015, 07:16 AM
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continuing my slow progress.

powdercoated a few more parts. still working on wiring my hand controls. they are a bitch. very limited space in both bars and housings. also had 2 switches break.

left hand controls, mirror, grip:




foot controls, velocity stack:


i had trouble deciding black or gold for the grips/pegs but eventually decided that i wanted them to pop. black would've just blended in, and after all the work i put into those i want them to stand out when you look at the bike.

also got my tank back with the mounts welded. list is getting very short, but still some big things:

-Finish hand wiring and debug all wiring
-Seat
-Exhaust
-Finish tank (pressure test, lab metal filling, sanding, 3-4 coats of powder, wet sand, buff, wax)
-Fill with fluids, adjust clutch, etc. try to start!

think i can be done sometime in July, barring major issues.
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  #90 (permalink)  
Old 06-18-2015, 03:30 PM
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Impressed ... love the updates.
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