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  #1 (permalink)  
Old 11-13-2005, 09:37 AM
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Phantom Front End Assembly Tricks

Before I begin, let me state for the record, that I am not an expert builder. I just happened to learn a few things assembling my Phantom front end that I would like to share.

The first time I did this, I scratched the fork tubes something awful because I didn't understand the instructions supplied. The following pictures will help to make the process of assembly easier by showing you what to watch out for.

These are just a few tricks and not the entire assembly instructions. Please refer to the instructions provided with the kit for more details.
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Old 11-13-2005, 10:02 AM
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Step 1. PROTECT THE CHROME AS MUCH AS POSSIBLE!

Yes, I used a ton of painter's tape because I am still mocking up the bike and will have to pull it apart one more time before final assembly.



Step 2. Assemble the internal fork stop to the bottom tree, slide on the seals and bearings. Insert the tree into the neck followed by the top bearing, seal and cap.

I'm assuming that you have already installed the bearing races into the neck. All frames are a bit diffferent and some use neck cups and other do not. My frame is a DNA and has a fork stop tab built into the neck. All I needed was the bottom fork stop plate and the stop pins. My bearing races went directly into the neck.

Fully assembled trees:



Don't overtighten the neck bolt. The trees should have just enough tension on them to keep them from flopping over on their own. Just a slight drag of resistance is all that is needed. On final assembly you will use locktite.
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Old 11-13-2005, 10:07 AM
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Step 3. Check for burs inside the lower leg openings!!

I sanded the inside with 600 grit to completely remove all burs. The first time I did this, I thought there weren't any but I was wrong!!



You can see the bur marks on the inside after sanding. CHECK BOTH SIDES!

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Old 11-13-2005, 10:13 AM
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Step 4. Oil the brake line passageway.



I used the sandpaper again to take the edge down where the cut out is for the brake line. (Inside the top cap) It's kind of sharp and the brake line gets scraped when you push the line through. Use some oil or grease in the passageway to make the line slide through easier.

Check the threads for burs and then apply some never sieze to them before assembly.
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Old 11-13-2005, 10:21 AM
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Step 5. Screw in the spreader bolt part way.



Step 6. Use a piece of tape to hold the washer where it needs to go.





Make sure the washer DOES NOT protrude into the fork opening! The tape will hold the washer in place while you screw in the spreader bolt to widen the gap.



You are going to need to screw it in about 3/8 - 1/2" after you hit the washer. Don't over spread the tree!
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Old 11-13-2005, 10:37 AM
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Step 6. Prepare the forks for assembly.

You are going to need to protect the chrome for insertion into the trees. Since this is only mock up for me, I covered the entire fork tube with painter's tape. You can use the clear plastic sleeves provided instead, but this is safer.



Note that the tape also acts as an index on the bottom to keep the brake caliper from spinning. This will keep the brake line from coming loose on the inside as well.

Step 7. Route the brake line through the passageway.



This step took two people to do while one holds the fork leg.
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Old 11-13-2005, 10:41 AM
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Step 8. Wrap the plastic sleeve on the fork leg and insert it into the tree. You will need help to pull the rest of the slack out of the brake line while the tube slides into place.

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Old 11-13-2005, 11:05 AM
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Step 9. Hold the fork tube IN THE CENTER of the opening, push up and start rotating the leg to screw it in. Don't let the fork leg rest on the lower tree or it may scratch while turning. It can be suspended in the hole (not touching any sides) with a little patience. TAKE YOUR TIME HERE!!

I had a second person twisting the brake line at the same time to keep it from getting kinked up inside the fork leg, while I screwed it in. You should both be turning in the same direction!



Once it is fully seated, you can remove the plastic sleeve.

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Old 11-13-2005, 11:11 AM
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Step 10. Repeat the process with the spreader bolt and washer on the other side.



Put never sieze on the threads, wrap the plastic sleeve around the fork and carefully thread it into place. Use the same centering, push up and turn process as before.

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Old 11-13-2005, 11:19 AM
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Step 11. Final assembly only!

You will need to install the pinch bolts and neck bolt lock into the holes shown.



Here is the final shot of the forks assembled.



The instructions provided with the kit cover the fender assembly pretty well. I had to purchase some 1" fender spacers from Accutronix to mount my Fat Katz fender. Give Karla a call (623) 516-9600 and tell her you are from Club Chopper and she will hook you up!

You will also need a -2 brake line fitting to attach the line to the master cylinder. IT IS NOT PROVIDED IN THE KIT! Direct Parts can supply one.

That's all I have for now. I hope you find these tips helpful!
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Old 11-13-2005, 12:07 PM
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When you purchase the front end from me now, you have the option to have me add the fender spacers and the #2 fitting but that is only when you purchase through me directly. I use the same spacers from Karla. www.PhantomChoppers.com
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Old 11-13-2005, 12:10 PM
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karla cavenaugh has saved my day on more than one occasion, she is the bomb.

she oughta have a fan club.
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Old 11-13-2005, 12:13 PM
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If a guy wants to save some tape and the time it takes to put the tape on and take it off, he can spread the tree using the spreader bolt and then put the tape on the inside of the tree hole instead of covering the entire leg.
Also, I recommend that these are bench assembled and then put on the bike as you have better control on the bench.
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Old 11-13-2005, 01:19 PM
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I like the idea of using the tape to hold that washer too. Good job of detailing the process Shawn.
Jay, I like your idea of taping the insides of the bottom tree too.
Nice to have people sharing their ideas and experience here.
Thanks to all.
PS: Jay, don't spread the word about saving blue tape. I'm buying stock in the company now that Shawn's published his directions.
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Old 11-13-2005, 01:43 PM
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Quote:
Originally posted by Phantom
If a guy wants to save some tape and the time it takes to put the tape on and take it off, he can spread the tree using the spreader bolt and then put the tape on the inside of the tree hole instead of covering the entire leg.
Also, I recommend that these are bench assembled and then put on the bike as you have better control on the bench.
OH, that's what you meant about the tape! Man, I just don't get instructions the first time around. Oh well, better safe than scratching them a second time.
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