JTH's HD 883 Dual Sport'ster conversion

That bike is awesome! You've done a great job with it! Any chance you can get some video of it running on some trails? I would love to see it in action.

Thanks! Heres a not so great video, but shows it on some trails at our local OHV park.

http://www.youtube.com/watch?v=cRfvVlaunew&feature=relmfu

Nice work and very inspired by what you have done.

Thank you

We now have a thread going in the Vendors forum before our website comes up (taking time to get all the details in there). It lists the kits and prices, and a few other details.

We will take names on a list for now, but real orders once the website is up with all the terms and conditions stuff...

Here's the thread link:

http://advrider.com/forums/showthread.php?t=833547

The Carducci Dual Sport SC3 Build Notes pdf version is now complete and available on the Vendors thread via paypal - were getting there, one step at a time.

http://advrider.com/forums/showthread.php?t=833547

Back to design and development mode! Im starting the larger capacity gas tank design for the SC3 Dual Sport, so wanted to share the development and get youre feedback as it progresses.

The plan is to create a ~ 6 gallon plastic tank suitable for dual sport riding that will fit the 1993 to 2003 Sportster models (and possibly 2004+). It will be made for volume production and available for purchase thru our company. Timing is TBD, but im going to push to complete it early next year.

Here is some of the initial design work...

Getting the shape right so its 1) functional, and 2) integrates well with the design.

3D CAD is a great tool to do this. I hope to have the shape/look pretty close before any cost is spent prototyping.

I pray that the fuel tank won't cost me my arm!! Are you planning the peacock to be at lowest point of the tank or ? Will the tank be capable of withstanding drop-down abuse like the IMS tank?

I am definitely in market for fuel tank and clearly I shall put off my plan to purchase this which is cheapest big tank I could find on the market for the 86-03 model. The plastic design sounds like the tank might be a bit lighter than this one.

Edit: One quick question- would the designed tank change the setting of stock seat? I already have Day-Long seat and would hate to not use it.

...

Lookin good!!!!! Keep it going. I keep checking back every so often.....

I ran across it at AU. Cool!

Nice! Thanks for posting this. AU was well done this year and it was fun riding the bike down the halls of Mandalay Bay casino

I used Acad and Inventor to design the components so Autodesk invited me to show the bike there.

Heres an update on the gas tank development:

I now have a foam tank that was cnc'd from the solid model to do the test fit and see how the shape looks on the bike. The clearances are good and i think the shape follows the lines of the bike pretty good.

Heres a few pics of the progress...

Damn, that bike just keeps getting better and better! Nice work!

thats a good look

That does look good.

How many gallons do you expect it to hold? (Sorry if you said it earlier and I missed it)

Will it also be adaptable for FI Sportsters with a fuel pump?

Im shooting for a useable volume of 5.5 to 6 gallons. The 3D volume measurement is at 6.05 gallon, so i may add a bit more to compensate for the wall thickness and shrinkage.

Currently no, not for the FI models, but i plan to fit test it on some stock sportsters 93-03 frames like mine, and then the 04 model on.

For the FI models - Is the fuel pump in the tank? or outside of the tank?

On the big twins the pump is in the tank on the FI motorcycles. But, maybe it would be doable to get an exterier pump and plumb it into the fuel line on your tank.

Hey Boat Puller....note the front wheel size.....

A serious adventure heavyweight bike with a dirt biased design and he is running a 21" front....Im just sayin.

Hey JTH, I love what you are doing here. I love some "different" ideas and OOTB thinking. I would love to see this bike in person and comb over the details. Just beautiful work and concept.

My best riding buddy is a Harley guy but wants to get into ADV style riding and exploring with me so I sent him this thread to show him he could have BOTH.

I would never want to throw my opinion in on such a great build but if you would like an idea I see may help on this build....stop reading if not

Have you considered or looked at running a sprocket brake on the rear. You may save weight and compress some stuff. I personally have never been a big fan of that huge rear caliper and mount system on Harleys, maybe going to a smaller 4 piston Brembo or similar and then make a bracket to mount it on the drive sprocket like some chopper guys have done could keep braking power or possibly even increase it and cut a couple of pounds of unsprung weight.

Here are a few ideas just to make you think about it a bit...not telling you what to do at all, just thinking outloud and throwing it out there.
http://www.ebay.com/sch/i.html?_nkw=sprocket+brake