Project Cosette (Yet Another Sportster conversion)

Discussion in 'Some Assembly Required' started by WhicheverAnyWayCan, Nov 17, 2012.

  1. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    WAWC,
    I have to agree with Solo and Drjoe that those are WP Extremes 50mm.

    I have spent the last 2 days looking at hundreds of pictures of WP Xs and what few pics I could find of the last version of the Marzocchis and I am 90% sure that yours are the late 90s KTM WP Xs and not the Marzocchis I thought they might have been.

    Just to clarify, I am by no means the only person who has confussed the 2. The last versions of the both of those brands look VERY similar and I found adds for both brands for sale that even the owners were not sure what they had. KTM did use BOTH brands in the late 90s...even over lapping years.

    I would still take them into a good KTM dealership to make that last 10% confirmation when you have a chance.

    Thanx to others for helping ID these.
    #21
  2. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    In case some of you guys know someone who is looking for a custom paint job to make his Pre-04 sportster looks good, I have a matching custom paint front/rear fenders and oil/fuel tanks for sale over at ADVrider Classified. Also posted over at XLForum as well. If one of you are H-D forum or V-Twins forum member, feel free to post link here or at XLforum.

    [​IMG]

    Thanks!
    #22
  3. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Thanks guys! The seller who sold me informed me that Marzocchi made WP Extreme for WP and he assured me that they are the same to just go with WP 50mm fork seals. And he advised me that if I google them up I would find the fact there. So I'll just go with WP Xtreme 50mm fork seals.
    #23
  4. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,181
    Location:
    Shoreline, WA
    Had to laugh about Marzocchi making the WP's... really doubt that one. Having seen the insides of both up close, the zokes are a distance second to the WP's.

    I have a set of the stock springs from my WP 50's that were off of a 640 Adventure (the heaviest KTM that used these), you should measure yours to determine what's in there.... If you want to try the 640 springs, I'll make you a deal.

    The WP 50's were fitted to all KTM's in 1999 from 125cc's to the 640's and if yours are off of even the 640 I'd bet the springs are way to light for your use on the Harley.

    Here's a bad pix of the 'zokes, very different from what you have there!

    [​IMG]
    #24
  5. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    That's my thought exactly when I google and did not find a result so fuck it I said..

    Thanks very much for pointing it out about the spring on forks.. to tell you the truth I was bit concerned about whether the fork was able to handle the weight and thought about getting a different spring and heavier fork oil? Any thought? I'll have a look at fork spring then let you know. Maybe we will work out a deal.
    #25
  6. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,181
    Location:
    Shoreline, WA
    I tried several different weights of fork oil with no good results... then changed the springs to custom heavier ones and ran through the oil exercise again...

    if you want to optimize the forks for your weight bike, having the valving customized is pretty much mandatory.

    You can just send 'em in to a good fork re-builder to have that done, shortened, re-sprung and re-sealed all at once
    #26
  7. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    You may already know this, but worth mentioning.

    Fork oil will change the action of the forks, but valving is a better solution. However, both of those only affect the speed that the fork piston travels through the stroke, both up and down. That will never overcome too heavy or too soft of a spring for your weight.

    Springs keep the bike in the correct part of the valving. The valving is in stages and too soft of a spring will put the forks in a later stage of valving and often make it feel harsh and bottom easier, mistakenly making you think it needs heavier oil or stiffer valving....usually that is in the springs. Too heavy of a spring makes the rebound feel harsh and chattering on the initial stroke of compression.

    Getting the right spring rate first makes oil and/or valving MUCH simpler.

    I think you can find fork springs for the WP X50s somewhere. Like said earlier, they came on 640s and many heavier riders with gear used them so someone made heavy duty spring rates....find some still may be hard. Not impossible.
    #27
  8. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Progress is moving slowly lately as I am having trouble with my back.. I know it is job-related but my supervisor and my boss doesn't think it is.. long story short, I gave up waiting on the decision from NC Insurance Committee or my work's Worker Man Comp insurance to make a decision and I went to see my doctor so now it has been past the point of being reasonable and try to work it out without legal battle. Not sure where this will go from here but at least my doctor and lawyer agreed with me based on the video I was shooting it is job-related. Will see what happen down the road.

    Last week, I disconnected all the bolts and wires so the engine could be rocking (loose) and ready to be pulled out. And I set up the washing room removing all of my grandma junks then organized the room to work on the engine. Yesterday, my friends were kind enough to come over and helped me pull the engine out of frame and hauled it into the wash room. I didn't realize how heavy the engine really is! Yikes!

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    This week, plan to take top part of the engine apart. On lower part of the engine- replace the cam and inspect tranny plates, and replace chain shoe. Probably start the process of re-valve the KTM fork too.

    More later.. just thought I would post a brief update on the progress real quick tonight.
    #28
  9. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Oh yeah, left out one more part.. my friend who is now a welding teacher at school I went to made this for me.

    [​IMG]

    I am in between on what length(height) of rear shocks I wanted to use.. 13" or 14" or 15"? Maybe 16" When I contacted Progressive Shocks and asked them that if I purchased their shocks and find it to be short/long or not satisfied, could I return it for exchange or refund? They said no! :huh :loco Works Performance said they would prefer to get the height of the shocks correct although they can adjust it.

    So I thought maybe the simple and cheap solution of the problem would be to get my friend to make a bar and drill one hole at the bottom and drill few holes at top from 13", 14", 15", and 16". When I have time this week or weekend, I will mount rear tire back on and then put this bar on where the shocks are supposed to be to get the feeling which height I want to work with on my sportster so my feet doesn't stand up without heels on the ground when I am standing up. I am 5'11" tall so it is crucial to get right height for me.

    And this will allow me to move my bike from small working space over to my dad's huge shop and get my motorcycle lifter assembled then I can lift the frame and begin the process of removing harley's fork.
    #29
  10. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    That is a good idea on the shock bars to test height. You can cycle the wheel and see what kind of belt or chain tension you may need with the raised ride height.

    Yeah, I agree, I doubt any shock compant is gonna wanna trade out shocks if you get the wrong length.
    #30
  11. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Yeah, thanks! Now my biker buddies are wanting to borrow it! hehe


    On a separate topic, I got laid off from work today. :puke1 :scratch There goes some of my $$ for the project and saving up for the trip! :becca But fear not, I will be fine..
    #31
  12. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    Sorry to hear about that. Always sucks. Still a tough economy out there even with the "signs of recovery" we keep HEARING about.

    It is very rare though to have both aspects a good project needs, time AND money. I usually have the money but am swamped with work so NO time, OR work is slow and I have time but I can't spare any money for a project.

    Hope the work front gets better.
    #32
  13. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Woke up this morning.. checked my checking account balance as I do regularly to be sure everything is up to date and not off. To my surprise, my tax refund arrived! :happay Never before in my life my tax refund arrive in my account/mailbox exactly 7 days after I filed for it (filed on 4th).

    So now it looks like I got time AND some money! :clap So if I can put some of my tax refund $ aside, and get these parts off then try to sell them. (heads, jugs, and cams) Maybe I'll sell them sooner than later and use some of $ to buy parts.

    [​IMG]

    [​IMG]

    [​IMG]

    Remind you of Buell motor??
    [​IMG]

    [​IMG]


    Compare the jugs! On the left is 04 and later, and on the right is Pre-03. If you got a keen eyes, you will notice that fins are longer on the left (04+) than on the right and that is why I am changing to help improve air flowing to cool engine faster.
    [​IMG]

    [​IMG]

    The DPO (Dipshit Previous Owner) left this bolt with no teeth to unscrew them loose so I had to stop right there. I'll see if I can maybe heat it up a bit tomorrow and try to unscrew it loose. I tried using adjustable plier but had no luck.
    [​IMG]
    #33
  14. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    I planned on purchasing Carducci's(JimmyTheHog) Dual Sport fuel tank but he is currently working on that right now and it is not known what price he would sell it at? Also, I was laid off so with too much time but little money it dawned on me that I have 4 4x8 sheet metal in my yard so I thought why not make my own fuel tank? First, I will make cardboard as a cutting template and then make a wood molding fuel tank. The cardboard template is to cut metal sheet and wood molding is used to bend sheet into shape.

    So I discussed this idea with my father who has 40+ years of mechanic experience but now disabled. His philosophy is that man who dies with most tools win! :D He told me that for my budget wanting to save money he recommended me to get MuggyWeld and he has oxyacetylene I can use to gas weld tank together and all other projects I want to build for the bike. Panniers, top racks, etc. I never thought about it until now. He said that just about almost any heating source (propane, map, etc) would work ok but may take longer. Now that I checked it out.. it is awesome! How cool is it that you carry few rods with you for emergency and if something break in middle of nowhere, just use your propane tank or maybe MSR to heat and the rod melts welding metal together!! This rods is now a "must-have" for most ADV Riders doing RTW rides. :deal

    More later!
    #34
  15. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    That is interesting stuff.
    Just my observation, if trying to use propane or map gas the heat affected area is much larger than Oxy/Acetalene. You can focus the heat much better and in a smaller area with O/A. You CAN weld, braze, etc with map/propane but the flame is usually much larger, more like a rose bud tip on an O/A torch and it heats too much area.

    When possible I would use the O/A, but a back country or remote area fix up with prop/map is a viable option.

    PS, that engine block that was welded up looks like the old Caddy flathead that was in my '40 LaSalle. It had thrown a rod at some point and had a huge hole in the block. Someone had ponded the divet back down and stick welded the block back up, it still ran. Man the weld was horrible, but it held and didn't leak oil. Amazing what people used to fix and now we throw away.
    #35
  16. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    Guess what I got free from local H-D dealer?? :evil :D

    [​IMG]

    A whole 16" rim!! :clap So what to do with it you might ask?? I can get the $150 hub off it and use it with 17" Buchanan's rim that I will be ordering soon. :deal

    [​IMG]
    #36
  17. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    Nice score, never hurts to ask right..
    #37
  18. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,041
    Location:
    Seven Springs NC
    I am leaning toward purchasing TIG welder and still plan to learn MuggyWeld. MuggyWeld tech told me that to ensure that I get best result with thick metal to use oxygen with MAPP or Acetylene. The propane will work ok with 1/8" or less. This was enough for me to say TIG would be better since I am gonna want to use thicker than 1/8" for fuel tank using .90" or 1/4".

    And yeah! You know I am on good with local HD dealer and I get free parts from them here and there. Also, I get 20% discount with them. :deal However I don't abuse it that I use the discount only when I need expensive stuff like new heads but not least expensive stuff like oil and filters. Don't want to wear the privilege if you get my mean.
    #38
  19. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    1/4" for a tank???
    What kind of tank, M1 Abrahms?
    Most tanks, I.E. fuel, oil, water...are MUCH thinner like down in the 18 gauge range. Usually not more than 14 gauge in steel and about 0.090" in aluminum. So 1/4" is 0.250" and that makes 0.090" like 1/11".

    Car bumpers were not even made out of 1/4" in the 1950s. I'm just sayin.
    #39
  20. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    Hey you are asking where others got their rim from like JTH. You can get that 40 hole 17" about anywhere.

    But Woody's Wheel Works and Buchannans will have the rim and the spokes you need, if not in stock, then quickly made up.

    I have bought a wheel from Woody's before and he is an inmate here on ADV and really cool. A well respected vendor and poster here.

    Buchannans is also has a really good reputation in the motorcycle world and hot rod world. My buddy had the make him some custom 60 spoke SS twisted wheels for his Softail. Nice pieces, but WAY outta my price range on those wheels anyway.
    #40