JTH's HD 883 Dual Sport'ster conversion

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

  1. KMC1

    KMC1 There is no spoon.

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    Wow. I just stumbled across this thread and I have to say I am totally blown away. This is without doubt the nicest looking adv bike I've ever seen. I honestly don't think Harley has enough brains to realize the potential niche this bike opens up to an American brand - that said, are there any plans to offer any complete bikes? With my schedule and living situation, I'm not able to do much fab work and it would greatly increase the chances of me having one of these.

    Awesome, awesome job Jim. If you get out to Utah, I'd love to ride with you sometime. :freaky
  2. hogasm

    hogasm Adventurer

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    Makes me want to convert a sporty instead of buying a new KTM
  3. KMC1

    KMC1 There is no spoon.

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    Jim, I've been reading the thread to see if I could find this info without luck - how hard will it be to set it up for carrying a passenger?

    :freaky
  4. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Not silly, this is something im checking on now. They are sized for 54mm dia top tube / 60mm dia bottom tube, which are what the KTM 525 tubes are. Spacing is also same as the KTM 525 - width and stem length. So, you could slide in a complete KTM front end (stem bearings, forks, wheel, caliper, disc) as is. Im looking into the new Marzocchis for this too. Not sure about the honda/suzuki/kawasaki/yamaha/etc.. types.

    I'll follow with with more info on fits as i get the info.
  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Good point. The bike is pretty stable at speed and so far off-road its pretty good to, but i havent gone that fast off-road to be sure if it would help or be needed. I'll look into some of them to see what it would take.

    Thanks for the input.
  6. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Great input - thanks much. Yes, we are considering doing a limited production run build of 10x bikes. A one-off build is also possible, but the cost for the parts will be very expensive this way (but, if money is no object...:evil). Buying a lot of 10x gets the prices down pretty good, but still not high volume low costs.

    I'll be posting updates as we figure this out. If we do it, it would be probably be something like - Get 10x people signed up, you supply the bike and we'll convert it for you.
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thats high on the list to do as my wife wants to ride on it. The seat can be extended more where the tool rack is, but where to put the passenger pegs is the challenge. The stock sportster put them on the swingarm, but I dont think i want to do that. I'll be working on it after some of these other projects get done.
  8. Jnich77

    Jnich77 Been here awhile

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    Out of the countless builds I have spent hours reading on here over the years.. yours is by far the most amazing!
  9. old fart bob

    old fart bob Armchair adventurer

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    Have you plans to market this 6, I think it's six gallon tank? If so, keep me on your list of interested parties. Twice in the Upper Peninsula of Michigan and southern Canada I came very close to running out of gas so this tank greatly interests me. I have an '05-883.
  10. KMC1

    KMC1 There is no spoon.

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    Awesome. I've subscribed to the thread so I can keep up with things as they progress. I'm really excited to hear you may do a production run! :clap The passenger accommodations are not crucial in my expected usage of the bike, but you never know what life will bring, and this would be the last bike in my stable if I was forced to sell stuff....so it could happen.

    Again, just awesome work. :freaky
  11. kellymac530

    kellymac530 motorcycle addict

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    A longer seat and rear footpegs are definately NOT a MUST on DS and ADV bikes, but I have used them more than once when you need to get a buddy out of a bad situation. If they do not add too much weight or inconvienience, I usually fab up a pair even on my KTM 400/620/530 I have had. Nice cheap easy back up plan.
  12. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    KMac - Good idea. I may be able to make some pegs that fit in the extra shock mount holes on the swingarm. If needed in a pinch, i could quickly install them.
  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Yes, i do plan to market these. Im hoping to get close to 6 gallons as the solid model is slightly over that so with wall thickness and when mold shrinks a bit, it should be close.

    As for the 05 model - this tank is designed to fit the 93-03 Sportster models. I havent checked the 04-06 rubber mount models yet, but im hoping it will fit them. Theyre still carb'ed those years, so no issue with FI pumps like in the 07's and later. When i find out, i will post an update.

    The mfg plan for the tank, which is still firming up, is to begin the roto-molding process in March. Not sure yet how long after that to complete. Cant commit until the mfg agreement is firmed up.
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Luke - I looked into the Scott steering stabilizer and it turned out it was wider than my clamps would accept. So, design changed to accept this now. Im waiting on the mounting hole locations and then I'll see how it could mount.

    As i mentioned, the bikes pretty stable, but others may feel the need or want to add this - so, thanks for asking about it. It probably saved me a costly redesign effort.
  15. Danger4u2

    Danger4u2 KX500 is Danger4u2

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    I use Scott steering stabilizers (ss) on 2 of my bikes and they come into play all the time. I always thought more on the line of high speed stabilization but mine comes into play more often at low speeds. Most common for me (woods riding) are large exposed roots at an angle coming out of a creek. Sometimes I can't get good traction to get the front wheel up to clear the roots. The ss helps stop my front wheel from deflecting one way or another. Helps stop the "jerk the bars from you hands" feeling. I have one under mount and one bike with over the bar mount. Over mount can be swapped between bikes, the bars are in the way to remove the under mount. It's good you made your set up accept the ss.
    Another good selling point. Your thread has made many of us dual sport ride'n, non- Harley owners, stop, watch and listen. I thought I wanted a Phil Little SXR Street Tracker now I want SC3.
  16. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    D4u2 - I know what you mean about trail riding. Ive ridden trails for a long time, but ive never tried a steering stabilzer. I may have to give one a try and see.

    Scotts has decided to send me a dead body (so to speak) of their steering stabilzer so i can make the mounting provision accurately. Great customer service from Scotts - thanks Jake! :clap :thumb
  17. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    SC3 Triple Clamps: The new triple clamps design is done and now has the Scotts steering stabilizer integrated. It fits between the bar risers and under the handlebars. This keeps the stabilizer tower pin nice and short to minimize deflection.

    Next step - cut metal....



    [​IMG]
  18. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    If I am not mistaken, I think that the piece that hold fuel tank for pre-04 is located differently from the 04-06 and 07+? I tried to see if I could put a 04+ 4.5 gallons of fuel tank on my 98 and it would not fit due to different fitment. But you could always try to design the tank to work with both pre-04 and 04-06 (non-carb years) before producing them?

    And don't forget that I am also in market for your 6-gal tank :D :deal
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    That is the plan - I just need to get my hands on an 04-06 and check out the fit with my foam mock-up tank.

    This tank doesnt use the stock mount at the rear. It uses the frame backbone with rubber pads to support the weight of the tank w/ gas and to attach a bolt (clamped or welded bracket like the Storz tank) that goes thru the top center of the tank. It also has brackets on the front of the tank that mount to the 93-03 tank mounting points. These are to support any front-to-rear movement or inward deflections. Since the brackets bolt on, if the 04-06 have different mounting locations, then I can make different brackets if theyre generally in the same location.

    Anyone else out there with an 04-06 Sportster that has any info on tank mounting differences? Some pictures would be good to see.

    This picture shows the mounting brackets and center hole...

    [​IMG]
  20. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Heres a B&W monochrome pic my wife took - it was a good lighting day for pictures.

    I also just added the vent slots in the front fender for better air flow to the motor.

    [​IMG]