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Old 04-11-2013, 10:48 AM   #16
MotoBoss
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I like the rack with the add-on fender/light. Just dump the grab handle to make a flat rack making it easy to work around with the fender extension and the rack gives you a sturdy platform for mounting luggage.....plus it looks "dualsporty"


.......nice project...........again.
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Old 04-11-2013, 05:06 PM   #17
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thanks Boss, Hope it turns out better this time around as well

I got a little work done. Wife had a motorcycle trip to Kansas this weekend and left today so I spent most of the day getting her stuff ready and making sure all was well with the bike. Then i have kids to spend time with. I got a hoop made and cut the rear struts. well pics are best





no worries about the all tread I used it to keep every thing straight and level. In the last pic I have the wheel with the suspension bottomed out. Still have a lot of work to do but this is a start :)
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Old 04-11-2013, 07:01 PM   #18
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Interesting to see what you come up with version 2.0 of your sportster project..

I have one question.... You don't worry about it having the exhaust pipe that low when doing a river crossing? Or do you plan on avoiding river crossing? I am weighting my option on where I want the location of my exhaust pipe.

And I am also thinking about making an extension for the carb a little bit higher than its normal position so it doesn't let water in when doing a river crossing.
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Old 04-12-2013, 04:29 PM   #19
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No prob with water crossings and the carb is higher up than the Klr carb. That said if the water is as high as the carb. I'm not crossing
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Old 04-12-2013, 07:13 PM   #20
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I found this tail light for a bike I'm building, tailight, brakelight. turn signals & license plate light all in one.

http://www.ebay.com/itm/261198339955...#ht_2397wt_885
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Old 04-13-2013, 06:31 PM   #21
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Cool light, I like the dual light.


I have a new set of bars in. May just leave them wrapped until I get the bike ready to ride again.

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Old 04-14-2013, 08:47 AM   #22
k-moe
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Be sure to keep the decal on that rack. I find that confusing onlookers is half of the fun (seriously).
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Old 04-14-2013, 09:41 AM   #23
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I have thought about changing it to XLR1200GS
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Old 04-14-2013, 10:54 AM   #24
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So the numbers on the first page are not right. Not sure how I messed it up so bad but I did. the swingarm angles are off. After looking at it again to do I found that a shock with 14.250 length and 5.250 stroke would put the swing arm in the middle of its swing at 10* angle and 20* of swing. Add in rider sag and i set at 6* angle at ride height.

Now the chances of finding a shock with those dimensions is slim. So as in life I will most likely have to compromise the ideal set up. But I do have a goal to shoot at.


I have mocked up a rear under fender for the rack. I did not like the hoop I built and then the chances of it adding stress from only one mount on each side is high. Looks to me like when loaded it would want to pivot around that mount point.

So I will mount it all to sheet metal. here is my poster board test piece.
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Old 04-14-2013, 02:40 PM   #25
voyagerrider
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John,
I discovered this thread a few days ago and have signed on to follow this. Glad to see you are building another Adventure Sportster.
Marty
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Old 04-14-2013, 03:13 PM   #26
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Thumb

thanks hope it turns out better than last time and i loved it last time.

I was going until i put the yz forks on before I put the handlebars on. I just couldn't wait.





I'm going to go back with the HDB hand guards they are just to clean not to. It integrates guards blinker and mirrors all in one piece.



so all the H-D mirrors and blinkers are going bye bye
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Old 04-15-2013, 06:37 PM   #27
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got some work done today. Have the tail section made and bolted on. I like the look and the panniers will fit well.



I also made a couple of brackets to mount the gauges and the headlight.
I am digging the look of the sportster head light on the dirt bike forks



one day I will be blessed with a mill




dosen't look like much but it took a while to get it all done. the hack saw and file work takes the most time
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Old 04-16-2013, 05:43 AM   #28
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Quote:
Originally Posted by johnwesley View Post

dosen't look like much but it took a while to get it all done. the hack saw and file work takes the most time

I think that you and I have the same tool assortment.
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Old 07-29-2013, 06:06 PM   #29
WhicheverAnyWayCan
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What size of rear rim did you use? I think you said it was 17" but is it 3.00 or 3.50 or 2.85? I am about ready to do the wheel this week but couldn't decide on wide size.
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Old 07-30-2013, 06:16 AM   #30
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Quote:
Originally Posted by WhicheverAnyWayCan View Post
What size of rear rim did you use? I think you said it was 17" but is it 3.00 or 3.50 or 2.85? I am about ready to do the wheel this week but couldn't decide on wide size.
2.50 for dirt
3.50 for mixed use (honda transalp 700 africa twin, bmw 700GS)
4.25 for street (KTM990, BMW 800GS etc)

Given the weight of such a bike, I would lean towards the 3.50
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