JTH's HD 883 Dual Sport'ster conversion

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

  1. GrumpyOne

    GrumpyOne Been here awhile

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    Sorry if I missed it, but any idea when you might start selling "conversion kits"?

    Thanks,
    jw
  2. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    The mounting brackets are done for the Pivot Pegz. Here they are with the pegz installed. Should have pics of them on the bike soon.


    [​IMG]
  3. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    We plan to announce our prices and timing later this month. Everything on the business side is just about in place now.

    The parts will be build-to-order initially and we will need a minimum number of orders before we can pull the trigger on fabrication to get the lower prices.
  4. madrider5150

    madrider5150 Adventurer

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    I am really liking this idea! Any details on how you got it to fit? Also what kind of windscreen is that?
  5. madrider5150

    madrider5150 Adventurer

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    Jimmy, will the components be available individually or only buying all of them in a "kit" form? Looks fantastic btw
  6. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks! We plan to have "individual" kits, 20 total at this point. Swingarm kit, foot controls kit, triple clamps kit, etc... So, you could buy all 20 or just the ones you would want.

    For the parts we don't plan to sell (like the wheels, tires, chain, sprockets, handlebars, front fender, etc..), we'll have our build notes available specing those components.
  7. Ed_in_miami

    Ed_in_miami Cubicle Traveler

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    What a beautiful bike. It's a show-quality bike you can actually fling about and really use. Very-very cool.
  8. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Jimmy,

    How thick is your skid plate and what type of aluminum are you using? I am in process of ordering aluminum stuff for fuel tank, front sprocket cover, H-D speedo, and skid plate.

    I figured that Skid Plate is something I should do before I put engine back onto the frame. I was thinking of making a thread under the frame so I can screw bolt on to secure the skid plate. If you have better suggest, let me know.

    Thanks!
  9. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Today, I have cut off the bottom piece of cam cover just to trim off the dead weight. Of course, for me each pound count so I just wanted to rid of whatever unnecessary weight there is. And I found out that you could cut down Cam Cover like this below.

    [​IMG]
    [​IMG]
    [​IMG]

    My father help me with filing and sanding it today. I decided not to cut off some of the cover to the left where you can see the oil hose clamped on the bolt. I figured I better protect that piece. And that hole at bottom (top in pic) is for ignition module so I left it alone too. I was advised to leave the dowel (that hole at corner away from yellow piece) alone because it helps with aligning the cam especially off-roading even though it could be cut off too so that is 2 reasons for not messing with it any further. I'll sandblast and powder coat it on Friday.

    Anyway, I am planning a design for sprocket cover because Joker's Machine doesn't offer anything for Pre-04 sportster. They have it for 04 and up, and it weights about 1lbs 2oz. I haven't weight the factory one but I could tell it is pretty heavy so I am planning to have one made to replace the stock one to take extra weight off. Have you thought about it?? One thing that came to my mind when designing one is that I would want to access to the sprocket with my tool without removing it so I would make one with big hole in the middle while still providing a good protection. Any thought??
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    I used 0.156 thick 5052-H32 Aluminum, then hard anodized it. For mounting, I used the hole in the front frame bracket and for underneath, I made a bracket the fits between the frame tubes with a flange on top that sits on the frame tubes. The bracket is threaded. Then screw the skid plate to the bracket clamping the frame tubes. It work pretty good and no welding of tabs to the frame.

    I think I posted some pics of the skid plate somewhere on this thread.

    I also added a Delrin spacer plate between the bracket and skid plate that supports the skid plate for when you lift the bike with a floor jack. If this spacer is not there, then the skid plate would probably bend from the weight of the bike.

    Hope this helps.
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Sounds good, but I haven't looked into this too much. I did talk with Richard Pollock of Mule Motorcycles a while ago, and he has done some nice custom work on some of his Sportster sprocket covers. Maybe check out some of his bikes.

    http://mulemotorcycles.net/
  12. montesa_vr

    montesa_vr Legend in his own mind

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  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    I should buy stock in Continental tires - seems like everyone these days is putting TKC80's and just about every kind of bike. Even a Ducati Panigale I recently saw!

    I like the retro paint on the tank though :thumb
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Development of the plastic 6 gallon gas tank is now underway. Here is the start of the foam plug that will be used for the mold. It's a close replica of the Aluminum 6 gallon tank I designed and then hand formed by Evan Wilcox.

    The imperfections in the foam plug will be filled and sanded next...

    [​IMG]
  15. CruisingRam

    CruisingRam Frankenbike builder

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    Pm me price and availability when you get that tank done!
  16. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    I could be next in line if the price and release date is right.

    Question for you: 1) Will the design of this tank work with any type of triple tree or is it recommended to purchase your triple tree? 2) What type of plastic is it? Is it similar as one that IMS use on their 6-gal and 10-gal that is indestructible? 3) Have you thought on color selection for dying or is it paintable with proper primer?

    I just got wheel set from buchanan's on Monday so at this point, I am ready to assemble my bike back together(starting with motor, forks, wheel, etc) and if goes as planned, I could be needing fuel tank short after Christmas to fire up my bike. I am without fuel tank right now.
  17. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    The tank will work on a stock Sportster 93-03 but a seat mod is required and you need to weld on (or possibly clamp on) the mounting bracket.

    The material will be XLPE - yes, same as what IMS uses. There will be plenty of color options.

    Price is still TBD, but it will be much less expensive than the hand formed Aluminum versions.

    Timing is also TBD, but hopefully early 2014.

    Here's a test fit on a stock 03 883R with my SC3 seat. Works fine with the stock triple clamps.

    [​IMG]
  18. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Hmm.. I could get a 36" X 48" .090" thick 5052 plate for $70 delivered but handcrafting a fuel tank is still 'easy said than done' for me. Originally I planned for orange tank but I could go for black plastic tank and just slap orange HD logo sticker on it then call it a day! :D

    Too bad you are still on 'TDB' for price and release date. After I return from Colombia on Nov 20th, my first thing to do is work on fork and get wheels on the frame so I can make some modification to sidekick holder on the frame before mounting motor. It would have been nice to know info on tank so I can decide if I will want it and go ahead to modify the seat part before painting the frame prior to mounting motor. Anyway, would be cool to know info on what kind of modification is needed for seat holder. Thanks!
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    No mods to the seat holder brackets are required. The front of the seat just needs to be shortened a bit.
  20. SkiFastBadly

    SkiFastBadly A beer? Yes, please

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    Tried to connect with Jimmy at a conference this week. We missed each other, but his bike was on display and the comments were about what you'd expect...

    "Now, THAT'S a Harley I would ride."

    Nice job.

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