Ozzy CFL build

[Aussiechop]

Hey guys, thought I'd start a build log of this CFL I bought, have had a few issues and I'm only messing with the front end!
I can just see this being a headache after head ache, and the dude I bought the kit off isn't too much help, thinking about going going straight to MMW for some info. I think my biggest drama is just finding things that fit, and knowing what parts have to be altered to fit.

After unloading the pallet


My first problem was the front disc rotor wouldn't fit on the wheel, but I machined the center out a bit to make it fit, so that's sorted.


Now, I'm using Ultima break calipers and ultima front brake caliper bracket, the bracket is not going to fit, anyone know what brackets do fit?




And how it sits so far..

[HellionsMC]

Post deleted.

[flysocal77]

Looks like you bought a kit and need to assemble? My suggestion is to post your build here along with any problems you are having. Prior to my build thread I knew nothing about building a bike and bros on here are very helpful. Your brake problem was spotted by hellion very quick. Best to post up, do some reading on other build threads and let us help you out. Building a CFL is not easy so expect some more headaches.

[Aussiechop]

That's what I thought, cheers guys. Yeah it is pretty much a kit, I bought it off a guy in the eastern states of Australia who does a kit similar to SMW and their Godfather bike. So I'm thinking most of these parts would be more suited to the SMW style frame, unless he's doine some research on what parts this frame would need (and I doubt he's done that, look at the brakes.)

I've been reading into some builds here, so much good info to find.

So when you say pre 2000 and post 2000, you're referring to models? Of Harleys perhaps?

It looks like the caliper bracket won't do then, Unless I can get one made up, how would I find out what I'd need? Do I need to get info on the forks and then go from there to see what brake parts they suit?

[HellionsMC]

Post deleted.

[Aussiechop]

Alright, thanks for the info Hellion. I've put the front and rear axle though the the wheels and they fit all fine. And some of the parts I've looked at do have Big Twin or Softail labels on them (the rear brake bracket, motor mounts, tanks mounts etc) so maybe my supplier did do some research after all.

I'll talk to my dude tomorrow and ask him what year these forks are based on then, and track down a caliper bracket, and probably another caliper to suit, shit this could mean I may need a new disc too.

[Tink]

Not sure about that seat position, looks a bit low :-)

Tink

[DarinZ]

Yeah man, looks like all you need is a caliper bracket for a 84-99. Make sure you specify what diameter rotor you have. Should be fine to use your rotor and caliper with the right bracket, Center to center mounting distance and angle is really the only difference pertaining to . Like Hell said, 84-99 / 2000 and up is what your dealing with her. Don't get discouraged yet

[El Skitzo]

Are you aiming to get this bike legally registered here in WA? If so have you been through the process of engineering an ICV for rego in WA before?

[Aussiechop]

Alright cheers, I'll look into some 84-99 caliper brackets.

Tried mounting up the rear disc and sprocket, same deal, going to need machining. It's fine because I can do it for free, but the amount I need to machine may be cutting it close to the mounting bolt holes. But I guess theres not much I can do about that.

Skitz- I am looking to get it registered, haven't done the process before, All I know is I have to take it to an engineer to get the frame tested, to test the brakes, and then pass the pits. I've taken 2 bikes over the pits before so I know all their shit.

[Aussiechop]

Strange, I've looked into 84-99 HD brakes, and it's coming up with the parts I have. I've emailed my supplier asking for details on the forks, hopefully I can get some answers and I just haven;t got the bracket the wrong way or something. Looks right to me though..

[DarinZ]

Ok well then your lower legs are 2000+. Easy way to tell is measure center to center caliper mount holes. 84-99 is 3.5" and 2000 up is 2.75"

[Aussiechop]

Yeah you're right Darin, just measured, my fork holes are 2.75", on the bracket they're 3.5". So looks like I need 2000+. I'm glad I know what I need now, but, does the 2000+ caliper come separately as caliper and bracket, because all I can seem to find is them as one unit.

Also measured my rotor, 11.5" diameter.

[El Skitzo]

Originally Posted by Aussiechop

Skitz- I am looking to get it registered, haven't done the process before, All I know is I have to take it to an engineer to get the frame tested, to test the brakes, and then pass the pits. I've taken 2 bikes over the pits before so I know all their shit.

Yeah and then some.

First off you need to talk to the Department of Transport and lodge an application form to build an ICV (Department of Transport). Not sure you can find that paper work online, but you'd definitely get what you need from the Welshpool branch.

The Dept will also be able to give you a list of approved Engineers that they will deal with, and you'll need to talk to one sooner rather than later. Like you've heard, they will probably want to inspect all the bare welds on the frame, X-Ray the welds on the neck, and possibly stress test the neck as well.

You'll also need to get hold of a copy of the Australian Design Rules from DOTARS, which I believe they can send you on CD for about $5. In the eyes of the law you're not just building a bike to take over the pits that meets the WA road rules, you're manufacturing a 2012 model motorcycle and as such you have to comply with all the relevant 2012 ADRs and be able to prove it (hence the Engineer), just like any other major motorcycle manufacturer.

The ADRs will tell you all the regulations regarding dimensions of your bike, such as allowable wheel base, coverage of fenders over tyres, handle bar height, min/max width, length of exhaust, positioning of indicators, side and rear reflectors, tail light, license plate, headlight, size of mirrors, which guages you have to have, which brakes and brake lines you can use etc. etc. etc. Every single aspect of a motorcycle is defined in the ADRs, and WA follows the ADRs to the letter!

Going over the pits will be very stringent this time around too as they will test and measure everything!! And prior to that you'll have done a lot of testing with your Engineer, like your brake performance (dry and wet), exhaust noise levels (both still and while moving at various speeds), emission levels etc. etc.

I've never seen a WCC framed bike in WA before, so make sure you have the MSO for the frame too because as far as the Dept of Transport is concerned, it may was well be from outer space.

Look forward to seeing it on the road though, that will really blow people away!

[Aussiechop]

Alot of great info there Skitz, thanks.

My plan was to mock up, then head to the engineer and get the frame tested, Getting the ICV from Welshpool will be no worries, I work near there.

My supplier is in Sydney, and (to my knowledge), is aware of all the ADR regulations, while I was looking for a frame, I wanted something like a 6" up and 6" out and he said I won't be able to pass that, and he recommended this frame and was even happier, The seat to bar length and the rake is all ok.

I may buy a second rear fender to comply with the 45 degree rule. I'm just not sure about the indicator positions, I have a license plate holder and light that will go on the rear fender. I have indicators also, and horn and tacho that has all the info I've seen on my other bikes (neutral light, speed, indicators, km's etc.).

The only thing that occurred to me was the emissions, this I'm abit scarred of. I'm buying stock harley pipes so it's quiet, but I'm not sure if these Ultima motors are emission worthy.

Also forgot about the MSO, I thought it was meant to come with the frame but don't remember seeing it.