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  #76 (permalink)  
Old 12-04-2021, 06:29 AM
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Long time no posting...
Things get in the way of custom building , lol.
A big step finally done , the rear wheel has reached its final configuration. Spacing the rotor 1/4" away from the drive sprocket was the final problem solved.
The wheel is centered , the rotor and sprocket spaced properly and it was torqued to 90 ft. lbs. and turns very smoothly and feels and looks great.

Chain run checked and remains proper:

This is now a workeable real wheel setup and is ready to be chained up!
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  #77 (permalink)  
Old 12-21-2021, 08:35 AM
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Another big step realized with the chopping down of the 1/25" hamdlebar ends to 1". I want to have the controls on the bars as well as the switches.
Here are the 1" sections one in the handlebar one to show:

Both ends done:

Lost some of the powder coat on the ends from the welding:

Not too bad and had to be done...
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  #78 (permalink)  
Old 12-21-2021, 08:43 PM
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Wanting to get this done ,I kept at it. Laid out the area to be removed for the master cylinders to fit the 1.25" section of the handlebars , sanded it out and cleaned up the work:

That exposed metal was tigged up and resanded, the master cylinders fit perfect and evenly on both sides:


Powder coat was burned away a little, but that was forseen, i have a plan for the burnt area:

Nice fit on the masters!
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  #79 (permalink)  
Old 12-25-2021, 01:55 PM
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Quick Xmas morning pic , progress is ongoing and evident:
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  #80 (permalink)  
Old 12-30-2021, 02:20 PM
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Pic to show the melee of tools and supplies needed to wire a bike, also the front wheel spacing done , handlebars modded for controls , main chassis wiring is near completion , engine wiring left to do:
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  #81 (permalink)  
Old 01-06-2022, 12:49 PM
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Rear fender on. Lots of mods made tougher by the final paint finish being applied by the previous owner. Plenty of masking and careful work gets it done:

Triple mounting bolts with a .25 inch backing plate ensures a tight and secure fit:

Steady progress.
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  #82 (permalink)  
Old 01-08-2022, 04:01 PM
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An issue with the speedo light required some attention. Having wired over 50 choppers , not one of them was perfect right out of the gate. With so much to think about an errant wire or two , or missing wires is perfectly normal. Such was the case of the speedo light, I neglected to supply power to the sensor wire , even though the lighting for the speedo is a seperate set of wires...
Go figure , and thats what I did...
The ceremonial lighting of the speedo (lol) signifies the completion of the chassis wiring , charging circuit and engine management wiring left to do.
The green led is neutral indication light.
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  #83 (permalink)  
Old 01-12-2022, 11:15 AM
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A piece of stainless steel - 2" x 30" x 3/16" - was worked into an RSD chainguard. I like using the stainless as it can be finished in a number of ways, I chose to brush finish the guard as polishing stainless can be a chore:

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  #84 (permalink)  
Old 01-23-2022, 01:18 PM
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Stainless work continues with the fabbing of the rear fender struts. 1" x 13" x 3/16" flat bar , slightly tapered to the top about half done:

And looky here what has arrived in the assy area:
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  #85 (permalink)  
Old 01-24-2022, 03:37 PM
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And finished:


Rear fender supported. In retro I would not have done this , the fender looked ok without them , but other reasons are there for the struts.

Hope you looky loos are enjoying this , I am , next up:

The Licence Plate & Tailight mount fabrication.
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  #86 (permalink)  
Old 02-06-2022, 06:05 PM
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Thanks for lookin'
So I put the engine in.
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  #87 (permalink)  
Old 02-13-2022, 07:57 PM
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Custom build problems come from all angles. The bike was assembled prior to my purchase of it. I did do a lot of fitting workas the frame was prepared and the engine and tranny and primary were in place. The engine and tranny went in for final assy after the frame was painted. I tried to fit the inner primary plate over the past few days and found a number of issues. First the plate would not line up and touched the frame. So it was clearanced a little. As the plate moved into position I could see that the 4 engine bolts were no lining up. Seeing it wasnt going to work I stopped and just started observing. It became clear that the tranny was sitting too low! lol How that happened I dont know. 250 thou too low to be precise , one quarter of an inch. So out came the batttery box , the tranny , and the oil tank was dropped down to access the tranny plate bolts all of it going pretty well. So some spacers for under the plate will raise the whole setup .
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  #88 (permalink)  
Old 02-15-2022, 08:30 PM
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Ya so after that semi -large setback , I set to it and spaced the tranny so that the primary plate slips on with hand pressure and seats with the slight pop any experienced mechanic loves to hear. Means it fits and fits properly. Everything went back on fairly easily for a custom, there will always be some tight areas . So out come the cut off allen key wrench's!
Horny lookin' primary plate in place:

Some parts should go on pretty easily from here , but rest assured another issue will come along soon enough. I'm happy with the work completed here.
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  #89 (permalink)  
Old 02-16-2022, 08:49 PM
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Rolling right along. All went well until the outer bearing support covers were tried on , they both required lathe work to fit, and off center work at that. Not everything fits out of the box. Both were machined until they slipped on with out pre-loadong the bearings:
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  #90 (permalink)  
Old 02-19-2022, 10:26 PM
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Coil mount revisited.
With the engine in some spacing was required ( go figger) I was gonna spend all day on some stainless spacers but found 2 nice chrome ones. Did the plug wires too:


And the burlwood cover to match the ignition switch 'dash' , here in file form to come off the CNC router:
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