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  #76 (permalink)  
Old 12-04-2021, 07:29 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, 09:35 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, 09:43 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, 02:55 PM
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Quick Xmas morning pic , progress is ongoing and evident:
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  #80 (permalink)  
Old 12-30-2021, 03:20 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, 01:49 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, 05:01 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, 12:15 PM
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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, 02:18 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, 04:37 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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