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
    A bottom view.

    The finish was supposed to be "clear" anodize, but turns out, the base material being 7075 Alum, the color came out gold - just like the gold KTM forks on the bike. A fortuitus mishap....

    Attached Files:

  2. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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

    Attached Files:

  3. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    looking good Jim. that swing arm is sweet :freaky

    Can't wait to see it finished
  4. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Oddometer:
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    Heres a few more shots of the arm...

    Attached Files:

  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
    Oddometer:
    741
    Location:
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    The chain tensioner has a small interference with the chain due to how its mounted. Will need to make a small mod the mtg bracket.

    Also, I thought the 120 links chain length would be just right, but when I originally did the full travel motion, I didnt have the master link connected, so it flexed/stretched a bit and seemed fine. With the master link installed, chain is a tad too tight. May have to add a link.

    Attached Files:

  6. SimpleSimon

    SimpleSimon Aspiring advrider

    Joined:
    Feb 28, 2007
    Oddometer:
    3,399
    Location:
    Lake Stevens, WA
    Adding a chain slider or guide?

    Looks fantastic imho. :D
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
    Oddometer:
    741
    Location:
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    Yes - Its a nylon slider/guide being machined now. The arm has some tapped holes to mount it. I'll have it on before and riding.
  8. jordan p

    jordan p projects > time alloted

    Joined:
    Nov 22, 2009
    Oddometer:
    128
    Location:
    Maui, HI
    I'm glad I just found this thread... I have kept track of most of the previous sporty adventure threads. I have an 87 rat tracker 1200 I just half assed created haha. I actually put it up for trade on craigslist for a big bore dual sport, but took it off the next day recalling my original reason for purchase 6 months ago...adventure. I have kids and literally no time for proper ingenuity and fabrication so I feel as if I will never achieve the quality I see in my visions. So budget adventure sporty it will be and I'll just have to work alot harder to get through the hairy stuff than everyone else! I am in san jose, so if you do start making kits etc, that will save me some dough on shipping !!!!!!! Your work is inspirational!
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  9. johnwesley

    johnwesley wanta be

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    mena, Ar

    so did you get a actual weight on the billet arm? Mine turn out 12.5lbs and I assume yours to be that or a little less

    I sent ya a pm
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Oddometer:
    741
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    I completely forgot :baldy - I was too eager to install it, that I totally forgot to weigh it. Im pretty sure its 13 lbs though. The cad program takes the exact volume, them multiplies it by the density of Alum., so I think the estimate is pretty accurate.

    I kept the truss walls pretty thick at 0.25 inch all over, so it doesnt surprise me that yours is lighter. I need to replace the rear brake caliber and rotor with something smalller and lighter to shed a few pounds.
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Oddometer:
    741
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    Hey Jordan - Thats what I like about the sportster - you can transform it into all kinds of bikes - tracker, cafe, dual sport,...

    Ive wanted to do this for years and was in the same boat with not enough time, but finally said Im not getting any younger, so just bit the bullet and am doing it now.
  12. Big Doobie

    Big Doobie Frustrated Redneck

    Joined:
    May 11, 2006
    Oddometer:
    539
    Location:
    Tater Country Pee-yay
    Really liking these dual sport sportster builds.

    Wish Harley would offer something like a Sportster Scrambler.

    Wish they'd make a modern Cafe Racer too.

    Wish I could buy 3 XR1200s, and build:
    an Evel replica street tracker in red white and blue,
    a blacked out cafe racer,
    and a cool dual sport like yours.
  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
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    While I wait for parts, Im mocking up the rear fender / sup-frame - the old school way.

    The idea is to make a fender out of thick aluminum plate so its structural and can mount a small rack on it (shown in previous post) and a plastic dual sport fender / brake light from Acerbis. Heavier than a plastic fender, but lighter that a tubular sub frame.

    I made a flat pattern out of carbboard and bent it up and taped it. Took a few tries, but I think I've got the shape about where I want it. Now to model it in CAD and create a real flat pattern and then have the part made.

    Looks a little crude, but you can get the idea of how it will look......

    Attached Files:

  14. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,404
    Location:
    On a set of 50,000 mile tires.
    Were you able to keep the swingarm at 20 degrees from flat like your drawings?

    Nice looking project.
  15. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks. No on the 20 deg. I ended up with 23 degrees in a neutral position - no load. I wanted 8" of travel, so thats what it ended up being.

    Im going to post the final geomentry next week - with 15.5" long YSS shocks.

    Shocks and exhaust arrive next week - unless the USPO loses em, like a tripple clamp I bought a while ago. Hope for the best.
  16. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
    Oddometer:
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    Location:
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    I worked on the design of the rear fender sub-frame today. Almost done. It will be 0.156 thick 5052 sheet aluminum and strong enough to hold a small rack to carry fluids and a small bag.

    Heres what its looking like......

    Attached Files:

    • RF4.jpg
      RF4.jpg
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  17. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,404
    Location:
    On a set of 50,000 mile tires.

    Thanks for the info, it looked like it got a touch steeper.
  18. xlcc

    xlcc Been here awhile

    Joined:
    Mar 23, 2011
    Oddometer:
    137
    Location:
    valemount,bc
    Man you are doin' an awsome job.nice to have acsess to that equipment.keep up the exellent work!
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
    Oddometer:
    741
    Location:
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    The long wait for the rear shocks is over - They arrived today :freaky
    Too tired to install them tonight. Tomorrow most likely so will post then.

    Can you tell who makes them ??? :evil Working with Klaus at YSS was a good experience. He's very technical and helpful.

    Attached Files:

  20. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Rear shocks installed and V&H SS2-R exhaust arrived today and installed. Getting closer...:freaky:freaky:freaky

    Muffler bracket was missing so I bent & cut an aluminum one up for now. Its too weak and flexible, so I will replace it with a stiffer one if I can still get it from V&H's (the SS2-R exhausts for the old sportys have been discontinued). If not, anyone out there have one they want to donate ? ...I mean sell ? :evil

    Nice kick-stand too ......

    Attached Files: