JTH's HD 883 Dual Sport'ster conversion

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

  1. johnwesley

    johnwesley wanta be

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    my plan was to use the stock mount on top. with the swing arm in full droop then the shock is 90 degrees from horizontal. With a slight angle fully compressed. If memory is right then I moved the shock mount 7.5" forward and it just cleared the caliper
    #41
  2. maxmfp

    maxmfp Dirt wannabe

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    I am very interested in how your bike is going to turn out. I ride a sporty myself and have been thinking about change my forks and shocks for years. The biggest change i did to mine is to put on a 6.6 gallon tank. Now i only have to fill up once a week. :D I will be watching for yours to Johnwesley.
    #42
  3. johnwesley

    johnwesley wanta be

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    #43
  4. maxmfp

    maxmfp Dirt wannabe

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    The tank was made for a DR650, i had to make a few changes but i got it to fit. I will post a pic when I find one (not sure i took one after i put it on).
    #44
  5. maxmfp

    maxmfp Dirt wannabe

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    Got some pics

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    #45
  6. maxmfp

    maxmfp Dirt wannabe

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    pic

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    #46
  7. maxmfp

    maxmfp Dirt wannabe

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    In the last pic the black ammo bags in the background are my saddle bags.
    #47
  8. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Now youre talking !!! - I was wondering if a big plastic tank could be fitted - now I know. Looks great. Thanks for the idea. At this point, Im not sure what tank Im going to do, but this gives ideas. :clap

    Thanks for posting.
    #48
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Same here - I have had a bunch of HD's over the years and have been waiting for HD or Buell to come out with a decent dual sport, but never happened ~ IMO. Finally bit the bullet and trying it myself. Not sure how it will turn out, but having fun in the process...

    So far, everthing is bolt-on, except the rear fender supports will get cut off. New swingarm is the most challenging so far, but we plan to use the stock shock top mount on the frame, so that will minimize the costs & no frame mod required.
    #49
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Ok - Finally converging on the swingarm geometry. It will be a left side monoshock. Time to cut some metal !

    Attached Files:

    #50
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Compressed geometry...

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    #51
  12. Keith

    Keith Slabbing it

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    Maybe I missed it somewhere, but how much wheel travel will 5" of shock travel net you?
    #52
  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Its ~8" travel at the rear wheel due to where the shock is located. The closer the shock is to the swingarm pivot, the less shock stroke required, but higher spring force required - leverage or moment.
    #53
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    The swingarm design is getting closer. Just need some finishing touches, then cutting metal.....

    Attached Files:

    #54
  15. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Bottom view.....

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    #55
  16. vtwin

    vtwin Air cooled runnin' mon

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    Wow, looks like a off road Sportster build off between you and RTWDoug.:lol3 Good luck to the both of you.
    #56
  17. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks. Theres a few of us right now including Johnwesley. Whats cool is that we all have our own twist on how we are doing it. Makes it interesting.
    #57
  18. Maxacceleration

    Maxacceleration Awol

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    Been following this thread.
    Just wow!

    The swingarm resembles the KTM Duke 690 swingarm with the exposed structure.
    Strong I would guess and also hard to clean, accumulating crud.

    Also the one thing I see is a lot of chain slack with the c/s sprocket so far from the swingarm pivot in Harley buildups.

    Have a good solution there?

    Fine work though! :beer
    #58
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Yes - Its very strong. Stresses are low relative to the 7075 Aluminum material. Clean ? - This is a dual sport :evil

    I hear you on the chain slack. There is a lot when you try to get this much travel on a sportster. Im going to use a chain tensioner as shown in some of my drawings, but here is a picture of it....

    Attached Files:

    #59
  20. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    A new part just came in .....

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    #60