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Thread: My sponsored 78 shovelhead build thread

  1. #76
    President: Big Cat Club Array newman's Avatar
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    Ok, got some work done on the neck.

    Check the earlier pictures for how it started.

    So i added on to my jig something to hold the neck sturdy. For anyone wanting to do this, a taper lock 1008 1.0 bushing like this



    will slide over a 1" shaft and perfectly center it in the neck like this:


    If you weld on the bushings they will crack, though.
    The above was used as leverage to bend the neck and also to ensure it stayed straight. The square tube that's been added onto the bottom of the jig served as a guide.

    I don't have a picture of the cuts before I bent it, but here is a picture of the cuts after i had bent the neck down.
    (Bending the neck down alone with 2 gimpy legs was not easy, i wound up running a strap under the acorn table and pulling on it from the opposite side)



    So then I beveled out the cuts and mig welded the shit out of it (3 passes). Did a little smoothing to the welds (it really didn't need it but whatever). The neck is actually cast steel, not cast iron like i originally thought, so it mig welded great.



    (sorry about the blurry pic)



    So then I had a moment of panic. I threw the level on the outside of the neck and it was way off. Like 2 degrees off (which would have moved the tire about 2" off center. I almost lost my shit wondering how I could fuck up so bad when I took a break and realized that they must machine the neck once it's welded onto the bike, so the outside is not parallel with the inside hole (which is what matters). So I grabbed a new 1" round and checked it for straightness (my last one bent while reefing on the neck) and installed it in the frame the opposite way like this, then hung a plumb line from it:



    Looks good. I threw the angle finder on it but as you move the level around the OD of the pipe the angle changes so it's pretty hard to tell what the angle is...



    But the plumb line isn't hard to read. Sits right in the middle of the backbone.


    I realize the backbone isn't the BEST judge, but it's a good second check!
    Last edited by newman; 01-08-2013 at 10:06 AM.
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  2. #77
    Lifetime User Array GV1390's Avatar
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    Bob needs more head punches.

  3. #78
    President: Big Cat Club Array newman's Avatar
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    First thing the italian guy thinks of is punching.
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  4. #79
    Lifetime User Array 97FormulaWS-6's Avatar
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    Newman - Always impressive work! Keep it up!
    I believe that there are some people out there that have such a bad case of chronic rectal-cranial inversion that they may be beyond help.

  5. #80
    Lifetime User Array focusinprogress's Avatar
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    Quote Originally Posted by newman View Post
    First thing the italian guy thinks of is punching.
    :like:

  6. #81
    Lifetime User Array GV1390's Avatar
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    Quote Originally Posted by newman View Post
    First thing the italian guy thinks of is headbutts.
    fixed.

  7. #82
    Lifetime User Array XwalkerX's Avatar
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    Quote Originally Posted by newman View Post
    First thing the italian guy thinks of is butts.
    Quote Originally Posted by GV1390 View Post
    fixed.
    fixed.

    ............__._ . ........... '55 FLH - '90 FXHT - '72 C10______________

  8. #83
    President: Big Cat Club Array newman's Avatar
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    Don't have a ton of actual work to show because I am waiting on dies for the bender and for my triple clamps to be waterjet cut, but I did come up with a pretty rad idea for the bars...

    Custom made BMX style bars that are clamped on the crossbar and then the headlight mounts in the normal stem location. I've never seen anything like it, but I think it looks pretty rad:





    Last edited by newman; 01-09-2013 at 11:02 AM.
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  9. #84
    Lifetime User Array focusinprogress's Avatar
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    thats a super cool idea, never seen anything like it before.....nice!

    What are you going to do for wheels?
    Last edited by focusinprogress; 01-09-2013 at 11:07 AM.

  10. #85
    Sr. User Array juicedz4's Avatar
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    Ya, thats def pretty cool.

    Dan

  11. #86
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by focusinprogress View Post
    thats a super cool idea, never seen anything like it before.....nice!

    What are you going to do for wheels?
    Please don't post that pic on CC or on your blog just yet... I don't want someone to beat me to the punch.

    Wheels are on order.

    16x3.5 and 18x2.15 (for 5.00 and 4.00 tire, respectively)

    Rear hoop haad to be custom drilled because I am using THESE hubs (in a magnesium anodize, silver rims/spokes)


    ---------- Post added at 10:27 AM ---------- Previous post was at 10:14 AM ----------

    I did get these axle plates back from the LAZAR:

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  12. #87
    Lifetime User Array jay_g's Avatar
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    I like this. Really showing your creativity and skill set.

  13. #88
    American Forum Vendor Array Carnut's Avatar
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    Have you rechecked the neck angle since welding?
    Them that don't know him won't like him and them that do
    Sometimes won't know how to take him

  14. #89
    Lifetime User Array focusinprogress's Avatar
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    I won't post anything about this build on any of my pages until it's done and it's in voting stages..... you have my word.

    glad you're going with spoked wheels, too
    Last edited by focusinprogress; 01-09-2013 at 12:55 PM.

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    +1 for slam bars

  16. #91
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by Carnut View Post
    Have you rechecked the neck angle since welding?

    Yep. Right on the money.
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  17. #92
    Lifetime User Array focusinprogress's Avatar
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    I keep coming back to look at the rendering of those bars and headlight mount. I can't beleive no one has ever thought of that. I REALLY like it.....for people who would run gauges, they could be mounted in the area between the crossbar and the headlight hanger and would really fit well into that void.

  18. #93
    Lifetime User Array focusinprogress's Avatar
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    I came back in here because I was having a chat on XS650.com with another fellow that is trying to turbocharge his bike with a DSM 14b......and I had a few thoughts pop up cause I remembered you wanted to boost this thing with an aerocharger....

    in your first post you mention microsquirt....gonna run something like a hayabusa throttle body(bodies)?

    Seeing it becoming more common to boost a bike, I'm really wanting to go with a little turbo and fuel injection on my CB550 big-bore motor build......lol. I miss having something "quick" in the stable.

  19. #94
    maxwell
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    Those bars are super rad and unique. I've never seen anything like it.


  20. #95
    American Forum Vendor Array Carnut's Avatar
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    Not that it's too much to concern about but food for thought. The bike has potential to steer heavy at slower speeds due to the rake and trail and that style of bar. It will handle similarly to a bike with drag bars based on where the bars clamp to the risers on the triple tree. Aside from the curve in the bars, its seems like they are on a straight plane. Not that big of a deal but something to consider.

    The headlight mounting is innovative.
    Last edited by Carnut; 01-09-2013 at 07:38 PM.
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  21. #96
    Lifetime User Array Spam16v's Avatar
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    I presume those bars will be custom vs. an off the shelf bar? I love the look.

  22. #97
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by Spam16v View Post
    I presume those bars will be custom vs. an off the shelf bar? I love the look.

    Yeah. Off the shelf bars would have almost no sweep to them because when they're installed like that rise becomes sweep and sweep becomes negative rise... generally those bars have very low rise angle. In this case they're drawn at the same angle as my custom honda bars. 15 degrees of sweep and -25 degrees of rise.
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  23. #98
    LS1 > LT1 Array joelster's Avatar
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    The headlight idea is pretty cool! You should hollow out the mount for it and hide the wiring inside and run it through the handlebar tubes, so it looks like it's just suspended in air.
    '94 Z28 BLACK LT1 n/a


  24. #99
    President: Big Cat Club Array newman's Avatar
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    Still waiting for dies and waterjet parts but I had to do SOMETHING so I made some risers. Sure I spent 5 hours making something I could have bought for 70 bucks but it's more fun and satisfying to make it.

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  25. #100
    President: Big Cat Club Array newman's Avatar
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    So over the summer I had a failed attempt to put 80's euro-only BMW M3 headlights on my Honda. The idea was cool but I think they just wound up looking too big and silly. I was trying to run twin 5.25" lights and it was just too much.

    For reference, here's an 88 E30 M3:


    And here's how they looked on my honda (just held on with tape, no housings)



    So i pretty much abandoned the project for the honda... However, since I'm still waiting for wheels and triple tree stock and my tubing bender dies i decided to revisit the project for the harley. Obviously dual ights was out of the question for a narrowed front end, but maybe a single light?

    So here's what i started with. It's hard to tell but the whole thing is like 7 or 8 inches long... too long for the bike...




    Then I took it apart and measured everything that I would be reusing, which was the projector, the reflector and the lens.


    Then I drew up my new light in cad.




    You can see how many parts I actually had to design in this exploded view:


    Once I cad a solid design down it was time to send it to the 3d printer. For those unfamiliar with such an item, it's TOTALLY AWESOME. One downfall is it lacks a lot of strength, so you need to make up for it in material volume and design. (for instance my shell thickness for the main body is about .5". Fortunately it's not heavy.

    Here are the parts being printed (along with some work stuff):


    It took 48 hours (yes, you read that right) to build. (it prints .0006" layers). Once the parts are done they are covered in a support material that needs to be cleaned off. It's sort of like wax. Here is what the parts looked like fresh out of the printer. They're nested a bit so it seems like parts are missing.


    Then you use a water blasting cabinet (think wet sand blaster) to clean them up:


    The detail on the printer is really amazing... this isn't even close to what it is capable of:




    Next i tapped some holes for assembly:


    Installed the projector:


    This guy holds the bulb. For final assembly it was painted chrome to reflect as much light as possible:


    Here it is installed:


    Then I tossed the back on.


    At this point it was clear everything fit together, so I pulled everything apart and painted it with plastidip, which is a rubberized paint in satin black.

    Here is the completed part. I'm not sure if I'll leave the brass hardware or not. The light is very sturdy, but I think I may rubber mount it just to be sure that the bike's vibrations and bumps don't make it crack apart.











    The wires will be hidden when installed. Obviously they need to be extended...
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