JTH's HD 883 Dual Sport'ster conversion

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

  1. Kennon

    Kennon Been here awhile

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    That fuel tank looks so beautifully made, could a clear plastic tank be made with the mould?
  2. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Offset is 18mm - same as the Applied Racing I had which worked nicely. Didn't want to mess with the geometry that was working.

    The price is still TBD, but since it would be a 1-off buy, it will be pricey Im sorry to say. If I were to get a group buy of 10x or more, then I can sell them for much less. I'll let you know when I have the price nailed down.
  3. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Tank alloy is 1100 aluminum. Thickness is .06-.08", but i need to confirm this.
  4. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Yes, it could. I have a 3D solid model of the tank that a mold can be made from or they could use the actual tank. Im still in discussion with the plastic tank mfgr - hope they decide to make this tank. The plastic roto molded version would be much less $$$.
  5. MitchG

    MitchG Iron Collector

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    Thanks Jim! This helps a lot.
  6. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Forgot to add: The 6 gal Aluminum gas tank weighed in at 9 lbs (tank + aluminum filler neck and plastic gas cap).

    That's only 4.5 lbs more than the Storz 2.75 gal tracker tank.

    New total weight of the bike ~ 479 lbs (with ~1 gal of gas)
  7. Kennon

    Kennon Been here awhile

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    what your doing is amazing, i'm currently in my second year of automotive engineering but I hope to get into motorbike design work afterwards this is really inspirational making a bike you want with what is already available.
  8. Bambi

    Bambi Been here awhile

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    Hello Jim,
    still watching your progress very curious, your skills and the skills of the people engaged in your project.
    Form of your tank isn't quite my taste, I'd prefer the Stortz one you had before or a more bulky version like the 80's/90's Dakar tanks, for example, of BMW, Honda's V-Twin or my own Suzuki DR Big 750. But the skills and the craftmanship of the guy who built your tank is unbelievable!!! On your pic, there is not a single mark to be seen that someone bet that aloy in shape, welded and finished it. As I said: unbelievable!!!
    Kind regards, Bambi
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Kennon - Thanks! That's a great degree and one I wish I had pursued myself. Once you have the engineering fundamentals, you can do just about anything you put your mind to.

    Speaking of inspiration - I recently met one of the head engineers at the Morgan Motor Company who was responsible for the Morgan 3-wheeler car/motorcycle development. A young guy. I was very impressed with Morgan's approach of blending the use of high tech engineering tools with old school hand crafting of metals and fabrics. Just amazing what they are doing and inspirational.

    http://www.morgan3wheeler.co.uk/home.html

    http://www.morgan-motor.co.uk/index.html
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    I guess its like art - it either does something for you or not, which is fine. This tank is an example of form-follows-function. When I decided to make this tank, I started with a spec: Capacity to get a certain range. Next was to keep the CG as low as possible. Then the ergos of leg clearance. Then the rest of the constraints of fit to the frame, motor contour, triple clamps, seat, etc. The result was the shape that it is. I only added some blends to smooth it out.
  11. theKite

    theKite Ulyssean

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    Hi Joe.
    You and I may be neighbors on the Sunny Coast. I am in Little Mountain.
    But what I need to know about pics, is just HOW do you attach them to the posts?
    Rob
  12. Kennon

    Kennon Been here awhile

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    Thanks Jim, been studying engineering in different areas for nearly 6 years now civil, motorsport and now Automotive hoping to get a job afterwards somewhere warmer to enjoy bikes on the road more its still currently winter biggest lie in England must be that the sun exists here.

    gone the sportbike route after 2 years on a supermoto, but will go back to dual sporting for sure the dream of a dusty dry gravel road is all too tempting not to pursue in, my preffered engine configuration is currently a V4 but have never ridden a thumping V-twin yet.
  13. kellymac530

    kellymac530 motorcycle addict

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    Wow Jimmy that tank is aluminum porn.
    Really incredible work.

    I can see where some might not like the exact shape of it, but I do not think anyone that has touched metal could look at that and not have utmost respect for it.

    I personally like the Form, Function, and the fabrication is flawless.
    Wow, all of those F's, I feel like I am in a Who song...."why don't you all F F Fade away, talkin bout my generation..."
  14. Bambi

    Bambi Been here awhile

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    Hello Jim,
    I've already seen the route that led to this shape of your tank. It's just own taste and riding style why I'd come to another version. I learned riding in the 70s and back then you sat more to the back of your bike, even on a dual-sport. And yes, you did sit much more than today and just got up in front of an obstacle and sat back down again when you had passed it.
    Today's riding-style puts much more weight on the front of the bike, including your own weight. So you need to be able to move much more forward on the bike than in the old days. I just didn't (couldn't?) adapt to this ...
    The seat of the actual Dakar-bikes runs up nearly to the steering-head and the front-tanks are much slimmer at the rear to enable you to stand most time of the day on your foot-rests. That's state of the art and style and it's the right way! You can see the result when you look at today's speed and handling during desert-races/-rallyes.
    Kind regards, Bambi ... a bit oldtimed ...
  15. sailah

    sailah Lampin' it

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    Jimmy,

    I purposely don't check into this thread for fear I will see exactly what I am seeing. That tank caused a mild mydocardial infarction.

    Your CAD skills are simply amazing. I have been getting by on Rhino 3D for simple planar structures and have recently become acquainted with AutoDesk Inventor which is great for 3D work especially when it comes to machine work.

    Your bike is amazing, please know it is being appreciated from all angles. :clap
  16. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks man! Ive been using Inventor and AutoCAD for many years now and think they are some of the best cad tools available, especially the new Inventor Product Design Suite. Ive used Cadam, Computervision, Ideas, Solid Designer, UGNX, and yes - the good old drafting board (ok, im dating myself :gerg), and they were all decent tools for their time and application, but Inventor is so intuitive and easy to use, powerful, and probably has the best rendering graphics programs around like Showcase.

    I'll put a "warning" out next time I post pictures :lol3
  17. Motomochila

    Motomochila Moto Scientist and time traveler

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    Great build! Nice to see the extra time you took in designing before fabricating. I'm on my 3rd project now and take far more time to design and test ideas before actually fabbing up parts that don't fit operate the way I wanted, but I went the other way. I took a dual sport bike and made into a hardtail cruiser. As for the time and money; What??? 2 years now? Short in the eyes of the manufacturers. Very impressive results. I'm about a year behind you ...and patiently designing, and waiting to launch my own 1st place finisher. Next for me is a Evo 1200 Dual Sport as well.
  18. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    finally made some progress on assembly of the new front end, gas tank, and crash bar.

    Since the Ohlins forks color are a bright gold, the rear swingarm ano of light gold clashed - so I re-anodized it the color of the sheetmetal parts - gun metal grey. I took a chance and left the bearing races installed for the strip & re-ano and plugged them, but murphys law prevailed - acid leaked in and ate the bearing surface. So, had to install new races. Not a problem since I had an extra set. Here's a pic...

    [​IMG]


    Next was the fit test of the new crash bar that mounts to the frame near the top motor mount. I didn't powder coat it yet in case rework was required. Fit was good though, so off to the coaters on Monday. I hope I never need to test it, but I think it will do the job though - its very stout! ...

    [​IMG]


    Got the tank and the front end installed and all the fuel lines routed. Came out pretty good and im pleased with the fit and finish. Put a measured 2 gallons in to start and will top it off soon to see what the actual capacity is. Im hoping for 5.5-6 gallons. Cant ride it yet as im waiting for a M10x1.25 banjo bolt for the new Braking front caliper. I had hoped the KTM bolt would work, but that thread is M10x1.0 - oh well. Heres a peak until I get the rest completed...

    [​IMG]
  19. ramon

    ramon weezin' the juice!

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    Looking good, Jim!!
  20. Rigger1221

    Rigger1221 Adventurer

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    Its an on going work of art Jim , like everyone here all waiting to see the final result.