Shawn1340's Softail Project

[Shawn1340]

Well, I am about to get started on the next wave of upgrades. I will be posting more pictures as the progress continues. To bring everyone up to speed, I have already completed the following:

Duece Turn Signal conversion http://www.clubchopper.com/showthrea...threadid=13295 What an adventure that was.
Lowered the rear by 1"
Upgraded to T-Bars
Changed the mirrors and grips
Leather dash panel
2 1/2" Stretched tanks w/ aircraft caps

Here is a recent picture:


I'm planning on taking this bike all the way up to a chopper. Since I can't afford $25,000 for a full bike kit, I decided to do it myself, one piece at a time. I'm starting out with $2500 in custom parts before I get into chopping the frame, etc.

Check back for new pics later this week. It's going to be interesting to see just how cool I can make a stock 93 Softail on a real low budget.

[Shawn1340]

Front turn signals and mirrors


Dash and T-Bars


Rear signals


Wheel nicely tucked in the fender


To really appreciate what I am doing, you need to know that I bought this bike back in 95 and never felt like changing it until now. I feel in love with this bike when Softails were first introduced in 84 and it took me 11 years to get enough money to buy one. I said I would never change it and rode it as is for the past 10 years.

[Shawn1340]

Here are the four reasons why it took me so long to get started on this project.



Family always comes first!

[Ace of Spades]

So Shawn, you gonna put a fat tire out back? Good lookin family you have there!

[Shawn1340]

You know it! That is planned as part of phase three, once the frame goes under the knife in phase two. Right now I'm replacing parts like crazy. Just got my pipes and braided cables in today.

[Hardtail99]

hey Shawn, since your gunna be putting your trusty ole mount under the knife soon, do you already have some specific dimensions in mind for the frame? will you be doing the frame work yourself ? I think this should be a very interesting project to watch, and a nice way for you to keep your ole friend in the family, I'm looking forward to following your rebuild, best wishes with your project.

[Shawn1340]

Originally posted by Hardtail99
hey Shawn, since your gunna be putting your trusty ole mount under the knife soon, do you already have some specific dimensions in mind for the frame? will you be doing the frame work yourself ? I think this should be a very interesting project to watch, and a nice way for you to keep your ole friend in the family, I'm looking forward to following your rebuild, best wishes with your project.

I'm planning on going up 4" and out 3". I'll probably have to get help since I don't have access to a frame jig and I will need help with the welding. Luckily I live a mere two blocks from Paul Yaffe's shop and I might ask him for help. It will probably be expensive but I don't know yet.

I'll probably get the wide tire right after that. I'm thinking somtime in the next few months, when I have more money to spend.

[Shawn1340]

Here is the next picture update.

Braided Fuel lines went in. Added a chrome carb cover as well.


Braided Oil lines were next.


Then the Hypercharger.




It's the little things like the crankcase breather hose...

[Shawn1340]

New Tri-bar Billet Headlamp with visor.




Here is a neat trick with the turn signal wires. Note how they feed into the bottom of the trees, using the factory holes. Since the bottom tree is hollow, it made it easy to hide them by routing them through it. They exit in the rear and just tie back into the harness. I just tried it and it worked out perfectly without drilling more holes.


You can guess what is inside, but you will have to wait for the next update to find out which pipes I actually bought.


Check back this weekend for more...I'm definately not done yet!

[Shawn1340]

I spent all weekend installing the braided lines and even got 1/2 of the forward controls on. That stock master cylinder bracket was tough to get off, having three side to cut off with my puny Dremmel tool. I ended up taking a cold chisel to it, to get it off the frame. Got everything grinded down smooth and painted for now. Later I can make it perfect. I wish I had better tools to work with. This probably would have taken you guys about five minutes to do. It took me over an hour with the engine still in the frame!

I'm still waiting on my rear brake line before I put the pipes on. It should be here in a few days with the speedo cable I'm still missing. I also got new cable clamps coming to make the braided lines and cables pretty.

Besides that, the kickstand is in the mail along with my replacement passenger pegs. The first set of pegs were dinged up during shipping. Got them from Bruce at Northwoodz Customs, who happily replaced them when I ordered my kickstand to complete the set. (I needed longer bolts to mount it anyway)

The last thing I got finished was the tail lamp bracket. I removed the lower supports and then remounted the license plate in the center of the backing plate, angleing it up a bit to match the curve of the tire. (I know it's hard to visualize, sorry) It looks fast!

I will post a few pictures tomorrow night, the camera is charging up now. Thanks for reading my saga!

Here is a photo of the new pipes I bought, for those of you who were waiting for it. (This is NOT my bike!)

[Shawn1340]

Here a few more pictures of the progress.

License plate modification - I think it looks much better without the support brackets and the new angle.


Master cylinder bracket removed. (I'll make it pretty when I do the whole frame) This was such a pain to get cleaned up with the engine still in the frame. It took an hour to get it this clean. (Pardon the bad paint, I needed to keep it from rusting for now)


Stock forward controls

[Shawn1340]

New Razor forward controls by Northwoodz Customs - SWEET!







New matching Razor Grips





The bike is now up on the lift awaiting the new brake pads and custom rotors. That is all I have for today, more this weekend.

[Shawn1340]

Well get ready to laugh, this is a good one!

So I'm trying to put on the front rotor when I notice there is no notch for the speedo sending unit. Then I take a closer look at the rear, which is installed already and I see that I have reversed the rotors! God I am stupid sometimes! Ok, most of the time, I admit it. I fixed it in under 30 minutes, including installing the front rotor. Man they look nice!

I had to change the rear tail lamp bracket because after I cut it, it was too weak to support the license plate without vibrating. Another dumb mistake but I wanted to share so someone else might prevent it from happening to them.

Here is a tip to save you a few bucks. Ace Hardware stocks good chrome hardware for replacing out those old tarnished bolts. I couldn't believe how many kinds they actually carry, SAE and Metric! After a few trips, I've got most of the obvious ones changed out. I also put some acorn nuts aroud the oil tank brackets. They look pretty good now!

I'm close to finishing the 1st phase at just over $3000 in better parts. If that rear brake line ever shows up, I will be able to put the pipes back on and take some good overall pictures to post.

[rwb]

Looks great Shawn !!

Glad to see someone customize what they have instead of dropping $15-20k on a kit !!!

I cant tell you how many stupid mistakes I have made on my build, how many wrong parts I have bought and how many times I have changed my mind !!!

Make your mistakes once....they will never happen again

[Shawn1340]

If any of you ever buy the Vance & Hines Big Radius pipes, You are going to need two of these:



They were not included in the kit and are required for Evo motors (1993).

A BIG thanks goes to Missy who stayed late at Hacienda Harley so I could pick these up before they closed! We need more women like her in this industry!

Now, where did those head bolts go to? I know I put them down on the bench somewhere...