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
    After I stuffed myself with bratwurst, I took a test ride in the Santa Cruz hills today - just went to synthetic motor oil and a pass-thru oil filter. Seems to be running about ~20degF cooler in like conditions. I like it :thumb

    [​IMG]
  2. onetravdown

    onetravdown I can't ride where?

    Joined:
    Jul 27, 2007
    Oddometer:
    924
    Location:
    .
    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.
  3. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    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
  4. DogTown04

    DogTown04 n00b

    Joined:
    Oct 10, 2012
    Oddometer:
    1
    Nice work and very inspired by what you have done.

    Thank you
  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    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. :clap :freaky

    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
  6. Ginger Beard

    Ginger Beard I have no soul

    Joined:
    Jun 24, 2008
    Oddometer:
    6,949
    Location:
    Sunny Northern Cuba (aka: South Florida)
    Congrats and good luck!!! The combination of beauty and functionality should make these kits a winner for anyone wanting a dual sport with an American soul !! :freaky
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
  8. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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

    [​IMG]
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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

    [​IMG]


    [​IMG]


    [​IMG]
  10. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,035
    Location:
    Seven Springs NC
    :clap :clap :clap

    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.
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    ...
  12. bravada

    bravada Adventurer

    Joined:
    Sep 18, 2011
    Oddometer:
    63
    Lookin good!!!!! Keep it going. I keep checking back every so often.....
  13. formulals1

    formulals1 Semi-Adventurer

    Joined:
    Aug 24, 2002
    Oddometer:
    309
    Location:
    NB, Texas
    I ran across it at AU. Cool!

    [​IMG]
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    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 :evil

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

    JimmyTheHog Low Speed Adventurer

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

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  16. onetravdown

    onetravdown I can't ride where?

    Joined:
    Jul 27, 2007
    Oddometer:
    924
    Location:
    .
    Damn, that bike just keeps getting better and better! Nice work!
  17. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    thats a good look
  18. boatpuller

    boatpuller Been here awhile

    Joined:
    Jan 4, 2012
    Oddometer:
    727
    Location:
    Central fly-over land.
    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?
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA

    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?
  20. boatpuller

    boatpuller Been here awhile

    Joined:
    Jan 4, 2012
    Oddometer:
    727
    Location:
    Central fly-over land.
    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.