JTH's HD 883 Dual Sport'ster conversion

[JimmyTheHog]

A bottom view.

The finish was supposed to be "clear" anodize, but turns out, the base material being 7075 Alum, the color came out gold - just like the gold KTM forks on the bike. A fortuitus mishap....

[JimmyTheHog]

Installed...

[johnwesley]

looking good Jim. that swing arm is sweet

Can't wait to see it finished

[JimmyTheHog]

Heres a few more shots of the arm...

[JimmyTheHog]

The chain tensioner has a small interference with the chain due to how its mounted. Will need to make a small mod the mtg bracket.

Also, I thought the 120 links chain length would be just right, but when I originally did the full travel motion, I didnt have the master link connected, so it flexed/stretched a bit and seemed fine. With the master link installed, chain is a tad too tight. May have to add a link.

[SimpleSimon]

Adding a chain slider or guide?

Looks fantastic imho.

[JimmyTheHog]

Originally Posted by SimpleSimon

Adding a chain slider or guide?

Looks fantastic imho.

Yes - Its a nylon slider/guide being machined now. The arm has some tapped holes to mount it. I'll have it on before and riding.

[jordan p]

I'm glad I just found this thread... I have kept track of most of the previous sporty adventure threads. I have an 87 rat tracker 1200 I just half assed created haha. I actually put it up for trade on craigslist for a big bore dual sport, but took it off the next day recalling my original reason for purchase 6 months ago...adventure. I have kids and literally no time for proper ingenuity and fabrication so I feel as if I will never achieve the quality I see in my visions. So budget adventure sporty it will be and I'll just have to work alot harder to get through the hairy stuff than everyone else! I am in san jose, so if you do start making kits etc, that will save me some dough on shipping !!!!!!! Your work is inspirational!

[johnwesley]

Originally Posted by JimmyTheHog

I dont have the official weight yet, but the CAD estimate is ~13 lbs. I believe the stock arm is around 10 lbs, so a bit heavier - but pretty stout. I'll have the official weight this weekend.

so did you get a actual weight on the billet arm? Mine turn out 12.5lbs and I assume yours to be that or a little less

I sent ya a pm

[JimmyTheHog]

Originally Posted by johnwesley

so did you get a actual weight on the billet arm? Mine turn out 12.5lbs and I assume yours to be that or a little less

I sent ya a pm

I completely forgot - I was too eager to install it, that I totally forgot to weigh it. Im pretty sure its 13 lbs though. The cad program takes the exact volume, them multiplies it by the density of Alum., so I think the estimate is pretty accurate.

I kept the truss walls pretty thick at 0.25 inch all over, so it doesnt surprise me that yours is lighter. I need to replace the rear brake caliber and rotor with something smalller and lighter to shed a few pounds.

[JimmyTheHog]

Originally Posted by jordan p

I'm glad I just found this thread... I have kept track of most of the previous sporty adventure threads. I have an 87 rat tracker 1200 I just half assed created haha. I actually put it up for trade on craigslist for a big bore dual sport, but took it off the next day recalling my original reason for purchase 6 months ago...adventure. I have kids and literally no time for proper ingenuity and fabrication so I feel as if I will never achieve the quality I see in my visions. So budget adventure sporty it will be and I'll just have to work alot harder to get through the hairy stuff than everyone else! I am in san jose, so if you do start making kits etc, that will save me some dough on shipping !!!!!!! Your work is inspirational!

Hey Jordan - Thats what I like about the sportster - you can transform it into all kinds of bikes - tracker, cafe, dual sport,...

Ive wanted to do this for years and was in the same boat with not enough time, but finally said Im not getting any younger, so just bit the bullet and am doing it now.

[Big Doobie]

Really liking these dual sport sportster builds.

Wish Harley would offer something like a Sportster Scrambler.

Wish they'd make a modern Cafe Racer too.

Wish I could buy 3 XR1200s, and build:
an Evel replica street tracker in red white and blue,
a blacked out cafe racer,
and a cool dual sport like yours.

[JimmyTheHog]

While I wait for parts, Im mocking up the rear fender / sup-frame - the old school way.

The idea is to make a fender out of thick aluminum plate so its structural and can mount a small rack on it (shown in previous post) and a plastic dual sport fender / brake light from Acerbis. Heavier than a plastic fender, but lighter that a tubular sub frame.

I made a flat pattern out of carbboard and bent it up and taped it. Took a few tries, but I think I've got the shape about where I want it. Now to model it in CAD and create a real flat pattern and then have the part made.

Looks a little crude, but you can get the idea of how it will look......

[larryboy]

Were you able to keep the swingarm at 20 degrees from flat like your drawings?

Nice looking project.

[JimmyTheHog]

Originally Posted by larryboy

Were you able to keep the swingarm at 20 degrees from flat like your drawings?

Nice looking project.

Thanks. No on the 20 deg. I ended up with 23 degrees in a neutral position - no load. I wanted 8" of travel, so thats what it ended up being.

Im going to post the final geomentry next week - with 15.5" long YSS shocks.

Shocks and exhaust arrive next week - unless the USPO loses em, like a tripple clamp I bought a while ago. Hope for the best.