Hawk 8

Discussion in 'Some Assembly Required' started by I Am Murphy, Jan 29, 2012.

  1. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
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    Taneytown, MD
    [​IMG]
    Finally got the zippers in. $2.00 each on Amazon, three days waiting for shipment, and three more sewing in the evenings. The pants are far more convenient to get in and out of...I just wish I'd had 'em when I got stuck in the rain for 30 more miles today. Oh well, I'm not used to the luxury of staying dry yet anyway. I received the Antron material yesterday, now it's time to tackle the planning that will have to go into lining the pants. The material looks pretty nice, and I made sure to get a little extra so I can line a full suit with color match.
    :freakyCheers!:freaky
    #81
  2. ben2go

    ben2go Moto Flunky

    Joined:
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    Upstate SC USA
    Beautiful work.
    #82
  3. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    [​IMG]
    There is still some final stitching and seam sealing to be done inside, but the Antron liner is in for the most part, and this morning offered the perfect opportunity to test 'em out.

    [​IMG]
    ...after a thirty minute wet ride to work this morning, the results are in. The next test will need to be much more stringent to really proof the concept, but at least I know I can get to work and stay dry...perhaps next time I will tuck my work pants into my boot as well...
    #83
  4. kellymac530

    kellymac530 motorcycle addict

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    so. cal.
    Were they warm enough?
    The damp bottoms is mostly because of wicking moisture from the bottom edge of the over pants. Tucking your regular pants into the boots first will probably stop most of that.
    #84
  5. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
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    Taneytown, MD
    I've worn them now down to 34 degrees. For my tastes they're warm enough, but I tend to prefer working on the bike in the summer's heat over being cold, and riding in the winter over summer's inescapable sun...so I don't mind a bit of a chill. I've got a full leather snow suit I put together two winters ago, I'll generally throw that on if it's below 25-30 degrees out, and honestly that is probably my favorite riding all year--the suit keeps you just warm enough, and just by chance I get this lucky breeze that runs up the legs and through the suit, perfect climate control. ...And your'e right about the wicking, we had rain all week here, but with the pant legs tucked in I stayed good and dry.
    #85
  6. kellymac530

    kellymac530 motorcycle addict

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    Good job. I am all about saving money when I can.
    #86
  7. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,037
    Location:
    Seven Springs NC
    Just found this thread.. am a little behind on few sportster building thread I didn't know until tonight..

    I see that you are done with the fuel tank there? Nice work! I am still contemplating on what I want to do about my fuel tank. Most likely going to build my own fuel tank but think I am gonna try to build a 6-7 gallons tank using 5052 H32 1/4" aluminum plate (think I can drop down from 1/4" to .90" but still researching). The reason I am going with that aluminum is because it came highly recommended by both hot rodders and airplane builders as it has no chemical react and is strong enough. I know some use 3003 (if I have # correct) but I just thought that I would share that info in case you might want to consider it for your Aux tank project. Also any idea how many gallons on your fuel tank?

    And interesting choice of fairing/dashboard. :thumb

    I'll follow your thread from now on to see what progress you have done as you go along.
    #87
  8. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    I like the aluminum idea, I agree with your sources entirely it's a great material and very workable. I don't have an exact figure and haven't really tried to figure out how much fuel my tank holds, but the based on the effect the change had on my costs at the pump I am guessing that the portion I cut out had little to no effect on the volume. But it didn't hold much to begin with, so I am anxious to put together an auxiliary supply system.
    Thanks for checking out the project, I'll have to stop by and see what you're working on!
    #88
  9. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    I finally had some free time to mess around with the Murph this week, and decided to use it to make the dashboard a little more maintenance-friendly. The switches I put in were done in a bit of a hurry and were wired directly from the solder points on the switch contacts to the terminal block below the seat. Even if those wires were to be quickly separable, the dash electronics are still interfaced to the bike through various harnesses and connectors of all different lengths and orientations. Separating the dash from the bike is a huge pain, and I aim to change that. When this is done there will be a new harness running the length of the frame and interfacing the dash to the system. The dash will separate from the bike cleanly, any wiring that stays with the dash will do so without hanging loosely.
    [​IMG]
    First I snipped all the switch wires, labeling the ends resident on the bike as I went.
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    I began crimping sockets to the switch wires on the dashboard, installing them into the Weidmuller connector and recording pinouts. Next I would cut the OEM harnesses and plan for their installation into the connector.
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    The OEM harnesses for left and right handlebar controls fit into the 24 pin Weidmuller along with the conductors for the turn signals. Still Have room left for three out of four switches, but I want to wait and use yellow insulated wires. The goal here, other than of course keeping the wiring compact and neat, was to zip tie the conductors in such a way that the Weidmuller connectors will act as though affixed to the dashboard back panel.
    [​IMG]
    On the other side I connected the dashboard wiring and indicator lights. Cutting the leads attached to the Vapor Gauge didn't turn out to be a standard operation, there was some sort of nylon inside the casing, and as small as the wires were it seemed less damaging to just melt it away rather than try to cut it. I still don't know if the gauge power and transducer signals will come through okay, but I can only find out by finishing the project. Got my fingers crossed. I trimmed and connected the battery gauge.
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    [​IMG]
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    ** These are here only as a personal reference **
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    Next I prepared to build the large control harness that would reconnect the dash to the overall machine, starting with the left and right signal connectors.
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    I passed the indicator signals through the 36 pin Weidmuller connector and bundled them to the left and right control signal harnesses.
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    I cut the yellow insulated wires to what I hope will prove to be an excessive length. I need to run about twelve more conductors to serve as spares before I can button this thing up, and while I hate stopping in the middle to wait for more wire, I believe it would be worse to need signals later and have to deconstruct or bypass the whole harness. The two large sections of shrink tube furthest to the left will just serve as guides, I'll shrink them in place to help create a solid form. The two to the right will act as end caps on a heat resistant fiberglass exhaust wrap. Once all the conductors are in place, the wrap will cover them from the front to a point just past the engine.
    #89
  10. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    Finished this a while ago, but was more excited about riding it than documenting it. Anyway, the wires had been laid out and labelled, the plans had already been drawn up in a full schematic, and all leads had been laid out with more than enough excess to account for changes or reroutes. By the time the spring hit and the air was warm enough to install it, it was a simple matter of deciding the routing, cutting to length and connecting per schematicsÂ…on to the next thing
    <a href="http://s1145.photobucket.com/user/rorykl/media/ADC8D6F5-3825-4733-8E4E-6A61D0023167-5618-000006E1DCFD6326_zpsa054da43.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/ADC8D6F5-3825-4733-8E4E-6A61D0023167-5618-000006E1DCFD6326_zpsa054da43.jpg" border="0" alt=" photo ADC8D6F5-3825-4733-8E4E-6A61D0023167-5618-000006E1DCFD6326_zpsa054da43.jpg"/></a>
    #90
  11. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    <a href="http://s1145.photobucket.com/user/rorykl/media/A0D2A3CE-4961-43C3-B6BC-3930FC977BEF-5618-000006E1BF969B6E_zpse5a9a1b0.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/A0D2A3CE-4961-43C3-B6BC-3930FC977BEF-5618-000006E1BF969B6E_zpse5a9a1b0.jpg" border="0" alt=" photo A0D2A3CE-4961-43C3-B6BC-3930FC977BEF-5618-000006E1BF969B6E_zpse5a9a1b0.jpg"/></a>
    With the wiring back in service I turned my focus to the chain. I had been hanging onto my belt to chain kit for a while at this point, so I was excited to finally get it out of my car and onto my bike. I enlisted the help of Earl Luhn of T-Bone & Earl's Cycle Shop in Taneytown; after our recent move, my bike is in a parking lot instead of a garage, and though I have many of my tools here, there are some jobs I don't exactly have the place or time for.
    <a href="http://s1145.photobucket.com/user/rorykl/media/5D8F815F-1DE3-4C84-9069-31B370FF6039-5618-000006E1CD8F2872_zps3dd1e1a6.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/5D8F815F-1DE3-4C84-9069-31B370FF6039-5618-000006E1CD8F2872_zps3dd1e1a6.jpg" border="0" alt=" photo 5D8F815F-1DE3-4C84-9069-31B370FF6039-5618-000006E1CD8F2872_zps3dd1e1a6.jpg"/></a>
    #91
  12. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    A lot of the OEM 883C parts sold quickly, but the original Sportster seat was worth almost nothin', and wasn't catching the interest of any buyers, regardless of price. So it dawned on me finally that I could take this seat of no interest and rip it up to make something smaller that would perhaps open up some fender space. Anyway, the idea at the cusp of this was that, the seat's of no value to me anyway, so if my upholstering skills turn out to be crap, I've learned an expensive lesson cheaply.
    <a href="http://s1145.photobucket.com/user/rorykl/media/AA35F71A-7094-4AF8-927F-07C2887F5257-5618-000006E1EE571EDC_zps5c2bc932.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/AA35F71A-7094-4AF8-927F-07C2887F5257-5618-000006E1EE571EDC_zps5c2bc932.jpg" border="0" alt=" photo AA35F71A-7094-4AF8-927F-07C2887F5257-5618-000006E1EE571EDC_zps5c2bc932.jpg"/></a>
    So I yanked out the staples holding down the fabric over the passenger portion&#8230;<a href="http://s1145.photobucket.com/user/rorykl/media/6B5B63E2-9B95-4082-AEEB-DB2F6938A448-5618-000006E1F9921341_zps6545ecb2.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/6B5B63E2-9B95-4082-AEEB-DB2F6938A448-5618-000006E1F9921341_zps6545ecb2.jpg" border="0" alt=" photo 6B5B63E2-9B95-4082-AEEB-DB2F6938A448-5618-000006E1F9921341_zps6545ecb2.jpg"/></a>
    <a href="http://s1145.photobucket.com/user/rorykl/media/4B78C6ED-C0C8-40A5-A9EF-484FAA468108-5618-000006E1FDED490B_zpsa3a7c78e.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/4B78C6ED-C0C8-40A5-A9EF-484FAA468108-5618-000006E1FDED490B_zpsa3a7c78e.jpg" border="0" alt=" photo 4B78C6ED-C0C8-40A5-A9EF-484FAA468108-5618-000006E1FDED490B_zpsa3a7c78e.jpg"/></a>
    &#8230;and used the reciprocating saw to rip the plastic seat pan in half.
    <a href="http://s1145.photobucket.com/user/rorykl/media/9BC62ED1-16DB-492C-B949-39A2BCCA4BAD-5618-000006E202ED5AEF_zps73bbea85.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/9BC62ED1-16DB-492C-B949-39A2BCCA4BAD-5618-000006E202ED5AEF_zps73bbea85.jpg" border="0" alt=" photo 9BC62ED1-16DB-492C-B949-39A2BCCA4BAD-5618-000006E202ED5AEF_zps73bbea85.jpg"/></a>
    I hacked up the foam cushion with a utility blade and bent the original mounting bracket with a hammer.
    <a href="http://s1145.photobucket.com/user/rorykl/media/35154B1D-DBE2-428D-ABD0-F8B19A1D5746-5618-000006E20A01B4CB_zps121e1f8d.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/35154B1D-DBE2-428D-ABD0-F8B19A1D5746-5618-000006E20A01B4CB_zps121e1f8d.jpg" border="0" alt=" photo 35154B1D-DBE2-428D-ABD0-F8B19A1D5746-5618-000006E20A01B4CB_zps121e1f8d.jpg"/></a>
    <a href="http://s1145.photobucket.com/user/rorykl/media/41EC6A84-765C-46E0-9BE1-2111A5CCDEB6-5618-000006E20ED41787_zps2ac6192b.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/41EC6A84-765C-46E0-9BE1-2111A5CCDEB6-5618-000006E20ED41787_zps2ac6192b.jpg" border="0" alt=" photo 41EC6A84-765C-46E0-9BE1-2111A5CCDEB6-5618-000006E20ED41787_zps2ac6192b.jpg"/></a>
    Thus far, I stopped after I folded the original fabric back and stapled it down. I am still hoping to re-upholster the whole thing and reincorporate the original "Sportster" stitching from the old seat&#8230;but it looks cool, and seems to be at a nice intermediary point for the time being.
    <a href="http://s1145.photobucket.com/user/rorykl/media/6BC025D4-C3D5-4803-9282-ECF52D61CB7D-6207-00000774FE7F988D_zps44965d12.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/6BC025D4-C3D5-4803-9282-ECF52D61CB7D-6207-00000774FE7F988D_zps44965d12.jpg" border="0" alt=" photo 6BC025D4-C3D5-4803-9282-ECF52D61CB7D-6207-00000774FE7F988D_zps44965d12.jpg"/></a>
    <a href="http://s1145.photobucket.com/user/rorykl/media/F5B2E3C2-F231-463F-8FC6-0443E6F913AB-6207-00000774F9B5C7C9_zps4a1e3851.jpg.html" target="_blank"><img src="http://i1145.photobucket.com/albums/o502/rorykl/F5B2E3C2-F231-463F-8FC6-0443E6F913AB-6207-00000774F9B5C7C9_zps4a1e3851.jpg" border="0" alt=" photo F5B2E3C2-F231-463F-8FC6-0443E6F913AB-6207-00000774F9B5C7C9_zps4a1e3851.jpg"/></a>
    #92
  13. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,037
    Location:
    Seven Springs NC
    Not a bad idea wrapping wires with heat wrap.. The fairing, is it something you can strap on to the fork tube? I think I read that this fairing from Canada company is what you can use to strap on to fork tube? And can you please take pic of the front of your sportster?

    I am just getting ready to powder coat my parts and rims but unfortunately it has been raining non-stop for past 3 weeks here in NC, which is not normal. Waiting for next window of opportunity to open up before I can do that. I'm powder coating metals outside using old swing frame with steel rod sitting on hooks so that's why..
    #93
  14. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    The installation of the fairing was slightly more complicated than just strapping on; it required some minor drilling/tapping, and I used zip ties to overcome a mounting issue at the very end, but all in all I think it was the easiest plug and play fairing you'll find - plus the guy who makes them and ships them is available by phone and is very helpful and friendly. I think his name is Ian.
    ...as for photos, there is an index on the first page if this blog, there you can see the exact page on which I laid out most of the installation, and I think I have a picture of the front end on maybe page 4.
    Thanks for checking it out! How'd the powder coating go, or have you gotten to it yet?
    #94
  15. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    My dad and I rode out to Johnson City, TN a couple weeks ago for our annual ride. Being in the saddle for so many hours a day was a great opportunity to figure out what improvements could be made to increase my comfort for longer treks.

    I came up with seven changes I wanted to make. The first was the addition of highway pegs, and the second was to soften them so I could lay my ankles out on long stretches of highway. I picked up a pool noodle for a few dollars, cut them to fit the length of the highway pegs, painted the ends black and wrapped them in duct tape. This was a simple solution that really seems to have added a new element of comfort. I was too excited to see this idea come to life to remember to take process photos, but the idea is clear.

    Next I wanted to take care of my sweet custom pipes. It's been several months since I put them on, and they were really starting to rust around all the rough welds. Since I have no intention of getting off the bike for a little rain, and I don't want to watch them rot out from underneath me, I knew it was time to take care of this.

    I started with a wire brush and cleaned up the headers. Once it was good I painted with high temp paint and set them aside until I could get to the rest.
    [​IMG]

    Working my way back to the muffler union, I taped off the I.D. plate and finished the paint work.

    [​IMG]

    Once the paint was cured, it was down to the wrap. I used to have this stuff on my straight pipes, and I really liked the way that an evenly maintained exhaust temp affected my throttle response. I've been wanting to set aside the time to do this for a while, and it came out as nicely as I had envisioned.

    [​IMG]

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    Here are the pool noodle ankle pads on the highway pegs. The black and silver duct tapes kind of help it to look like it belongs, and I'm hoping they will also serve to protect the foam when I smash my grubby soles into it.
    #95
  16. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    Something else that became painfully evident was how much my newly made solo seat sucked. I started by de-stapling the upholstery and yoinking the Sportster embroidery.

    [​IMG]

    That done, I borrowed my parents' electric carving knife to cut through a memory foam pillow. I began by cutting it in half.

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    Smashing the pan down into the foam, I marked around the edge with a Sharpie and cut out the shape.

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    I cut out the same shape twice, but leveled off one piece to make a base.

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    I used the left over material from when I made the water resistant leather pants to upholster the base in place, and then upholstered over the second layer.

    [​IMG]

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    I left the back open for drainage; I'm still not sure this was a good idea, but I guess time will tell.
    Next I sewed down the flap.

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    Never having made anything of this sort before, I took a page out of the book of boot making, and used strips of leather to make a Goodyear Welt around the base. The strips are stapled to the underside of the pan, and the outer leather will be sewn to the strips. My hope is that this will keep the outer upholstery from coming out wrinkly.

    [​IMG]
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    I rounded the corners on the top the sportster logo and sewed it to what will be the back of the seat.

    [​IMG]

    [​IMG]

    I used a pencil to mark the interior upholstery with a few ideas for the initial outer covering, and a Sharpie to line out the final designs. It was only after much head scratching that I figured out a way to cut my next pieces with minimal waste - masking tape! I filled the area I wanted to make a piece for with tape, layered it over a couple times, and traced my sewing edge onto the tape with a marker.

    [​IMG]

    The tape peeled right off when I was done. I attached it to the piece I wanted to use and cut along the lines. Now time to see how well it sews up.

    [​IMG]

    Â…and it looks like I've got a working model now.

    [​IMG]

    So I repeated the process for the front end

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    With the basics out of the way, I decided to take a hiatus to decide how I want to cover the rest and come up with a design plan. I'm thinking either a leather mosaic or stacked leather image. Most likely I'll try to incorporate an war bird and an 8, since the bike's proper name is Hawk 8.
    #96
  17. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    I threw together a few design ideas in Illustrator to try to help me decide with a side by side comparison.

    [​IMG]
    #97
  18. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    ...Down to the final two.
    [​IMG]

    I used the same tape and mark model as before to lay out a sheet that will cover the remaining area. My plan is to draw the final design onto the sheet, then I can cut out small pieces of leather to fill the shapes. Once all the pieces required for the image are cut, I plan to glue them onto the sheet, and then sew them to the sheet, and then to one another. With the design in place I will use the same technique to cover the rest of the cloth in leather, and then sew the resulting product onto the seat.

    I used the marked tape to cut out my cloth, marked the slightly imperfect shape for center, and checked the crosspoint with respect to the seat. All seems well, so now I just need to make a decision and get going.
    [​IMG]
    #98
  19. kalonji

    kalonji nihilism or nothing

    Joined:
    Sep 16, 2009
    Oddometer:
    2,008
    Location:
    Witness Protection
    I've been watching this show for over a year and a half. Keep it up and thanks.
    #99
  20. I Am Murphy

    I Am Murphy Vagabond Sportster

    Joined:
    Jan 28, 2012
    Oddometer:
    111
    Location:
    Taneytown, MD
    Finally done with the design work, I changed the head and feet of the bird on the right, and brought the 8 down inside the wings to get a little closer to what I was envisioning. It'll look a lot different once it's all Frankensteined together out of scrap leather, but this is going to be the base image.

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