JTH's HD 883 Dual Sport'ster conversion

Discussion in 'Some Assembly Required' started by JimmyTheHog, Feb 4, 2011.

  1. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    www.carduccidualsport.com

    Theres been some interest in this build, so thought I would post the development progress and hopefully get some insight from the inmates, as there are alot of challenges.

    Ive wanted to do this for years, but kept putting it off, but recently have seen a few nicely done conversions that have been the inspiration and ambition to finally give it a try.

    So, with a vision in mind, I started with a stock 03 HD 883 Hugger, 100th anniversary, that I picked up on new years ever last year. Next day began tearing it appart.

    Attached Files:

    #1
  2. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Tear down...

    Attached Files:

    #2
  3. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    KTM front end mock-up. Bearings and stem length are perfect fit...

    Attached Files:

    #3
  4. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Now the details:
    - Trail Tech 8" head light
    - Tracker 1" bars
    - Joker Machine 1" bar clamps
    - Applied Racing Triple Clamps
    - Stock controls - no rewiring required (grips gotta go though...)
    - Tach/Speedo mount custom designed & fab'ed billet bracket
    - Steering stop custom des/fab billet bracket
    - UFO front fender - KTM RFS
    - New brake line 52" sst from CC
    - Front wheel & caliper from KTM 525 - soon to have wider Sun rim for TKC80

    Attached Files:

    #4
  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Tach/speedo mount... sorry for the bad cell phone pic..

    Attached Files:

    #5
  6. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Steering stop - bolts to bottom triple clamp.

    Attached Files:

    #6
    sportyrider likes this.
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    So, the front end is mostly done. Moving on to the rear end - swingarm / monoshock mount.

    The plan is to mock up the stock swingarm with extensions to lengthen it, install the new 18" rear wheel, and get the geometry set right before jumping into design of the swingarm / mount.

    Here is the rear wheel from Buchanan's:
    - 18" Sun rim
    - Storz billet alum hub
    - TKC80 140/80-18

    Attached Files:

    #7
    sportyrider likes this.
  8. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Waiting for my swingarm mock-up extensions to come in from fab....
    #8
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Forgot picture....

    Attached Files:

    #9
    sportyrider likes this.
  10. marret

    marret Transient

    Joined:
    Jul 7, 2009
    Oddometer:
    218
    Location:
    Fort Knox KY
    Looking great.

    What year front end are you using?

    Thanks for posting.
    #10
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    The forks are from a 2003 KTM 525 EXC (which you see sitting next to it in sad shape) and have been reworked by Hlebo Bros racing suspension for a 230 lb rider. I dont have the specs as the PO did the work and didnt know.

    We'll see if they are adequete when the build is done. I had a dream last night that I was riding it and it worked perfectly...:D
    #11
  12. jphish

    jphish Been here awhile

    Joined:
    Oct 25, 2008
    Oddometer:
    622
    Location:
    Tumwater Wa
    Very Cool ! You are an Arti'st. Like a Ulysses - but a few steps farther.
    #12
  13. jphish

    jphish Been here awhile

    Joined:
    Oct 25, 2008
    Oddometer:
    622
    Location:
    Tumwater Wa
    PS: Final drive - chain or belt ??
    #13
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    It will be a 530 chain. The sprockets are on order: 24/51 tooth.

    The hardest part is the wait for the parts to come in !
    #14
  15. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    hey Jimmy thanks for putting this up looks like its going to come out great. This makes two builds going on in the forum with a sporty. I hope you guys stay far enough ahead of me to make it easier to follow suit. I already see I should have went with the ktm forks to make the forks a bolt on deal. We'll see how hard the conversion will be for the yz set up.
    #15
  16. JohnBoy777

    JohnBoy777 Pseudo-Adventurist

    Joined:
    Sep 8, 2007
    Oddometer:
    893
    Location:
    NE Ohio
    Jimmy,

    Great idea - thanks for posting.

    John
    #16
  17. John Ashman

    John Ashman Adventurer Wannabe

    Joined:
    Aug 17, 2008
    Oddometer:
    2,574
    Location:
    Viejo Mexico
    I saw an 883 the other day for the first time and it was the first Harley I've seen that I wouldn't kick out of my garage. I know it's the "girl's" Harley, but it seemed like a natural bike, not all glitzed and hyped to be super macho and stupid. Seemed like fairly decent ergos too.
    #17
  18. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    I just got my swingarm extensions for the swingarm mock-up. Insert them into the swingarm ends to lengthen it, find the right geometry, then begin cad design of the new swing arm. Mock-up pictures to follow...

    Attached Files:

    #18
  19. wpbarlow

    wpbarlow Long timer

    Joined:
    Jun 9, 2003
    Oddometer:
    11,622
    Location:
    Central NJ
    You have to name this bike "Silk Purse" :lol3
    #19
  20. Keith

    Keith Slabbing it

    Joined:
    Nov 29, 2006
    Oddometer:
    927
    Location:
    901
    Progress?
    #20