AIRHEAD TECH DAY BUILD

Discussion in 'Airheads' started by Scott in Missouri, May 23, 2019.

  1. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    At the end of the Tech Day, the bike was ridable again but I still hd a lot of work to do finishing it all.
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    #21
  2. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Controls are all modern. a new 17mm master cylinder, new adjustable controls, single pull Motion Pro throttle with a splitter and new switches. I would have to write a book on how to make all this work...I couldn't use the original stuff. Brakes are terrible and the throttles are so sluggish and have a lot of drag. I have the GPS and Grip heaters in the wiring to the Moto Gadget M-Unit. Lots to read about this in other threads. IMG_1987.JPG 57893778655__559C4025-8273-4912-93CC-B0B54C23E2D4.JPG 57893779967__A6B6C731-AFF2-4C4A-ACD0-37824E798360.JPG IMG_1856.JPG
    #22
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  3. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Finish work and installing new parts. The racks turned out nice and sturdy. The quick-release pannier mounts sure were a lot of work to get right, but almost look factory and not too ugly with the bags off.
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    #23
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  4. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Panniers mount nice with plenty of room. Lots of leveling and string used...the first one is easy to mount...matching the second one is what's hard.

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    #24
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  5. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Time to make the Honda Rebel fender fit. Cut off the old bolt holes and raise it up with extenders...make sure it clears the knobbies I have planned and weld it on level.
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    #25
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  6. Scott in Missouri

    Scott in Missouri Been here awhile

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    Feb 4, 2008
    Oddometer:
    284
    Lots of planning and measurements were made to ensure the seat would not only be comfortable, but transition to the top rack and panniers. The idea is that when all the racks come off the bike would still have good lines as a solo bike. The low bars can go back on or the high bars and all the hand protectors for long trips.
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    #26
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  7. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Reassembled and riding the bugs out again to make sure there are no issues when we ride to the BMW National Rally in Lebanon, TN.
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    #27
  8. 2WheelTraveler

    2WheelTraveler backinthesaddleagain Supporter

    Joined:
    May 29, 2013
    Oddometer:
    539
    Location:
    Tahoe
    Nice job, tastefully done!
    #28
  9. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    I still have a some items to change. I am mounting a fairing and a few trim pieces. I also have engine guards and LED lights.
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    #29
  10. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    No doubt I will be changing a lot of things and will update anything of significance. I tried to used a lot of pics to tell the story because I don't really chat back and forth here...mostly because some folks say the most thoughtless things and I get aggravated. However, I think it is important to give back to the ADV Community and share.

    Be inspired and build something~
    Scott
    #30
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  11. globalt38

    globalt38 "A Fist Full of Throttle" Super Supporter

    Joined:
    Apr 10, 2013
    Oddometer:
    2,134
    Location:
    Atlanta
    Very nice! :brow

    Love the pannier quick release racks - any chance you could show some pics of how the mounts on the panniers themselves look that mate to the racks?
    #31
  12. tlub

    tlub Long timer Supporter

    Joined:
    Oct 23, 2012
    Oddometer:
    2,322
    Location:
    Madison, WI
    Where are the turn signals? I'm pretty sure Federal law says that any bike of that era (post 1969?) is required to have them. They are also really nice to have so that cage drivers see flashing lights and sometimes, just sometimes, wake up.
    #32
  13. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Thank you Sir- That is a good question and I figured ADV folks would have interest in the Tusk racks and Tusk pannier mounts. I tried to cover it in pics, but it is a bit complicated so I'll try to make it simple. I ordered a set of KLR 650 items, honestly because KLR 650 was the cheapest available and I knew I was going to cut it apart. It worked out great to my surprise. These pics of the product are better than I can take and should answer your question pretty well. They are not super high quality, but are tough and durable...like an Airhead. :gdog

    I will tell you there is an inside safety lock/knob- Be sure to drill the hole and use it! The panniers will not fly off and slide down the road a mile from home on your first test ride...cough, cough...so I've heard. And they stop theft and rattles.
    Scott
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    #33
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  14. DinoBike

    DinoBike Dinobike

    Joined:
    Dec 8, 2006
    Oddometer:
    5
    Location:
    Washington
    #34
  15. DinoBike

    DinoBike Dinobike

    Joined:
    Dec 8, 2006
    Oddometer:
    5
    Location:
    Washington
    Yo Scott, you are the man! That thing looks great!
    #35
  16. Carbyhead

    Carbyhead Adventurer

    Joined:
    Mar 24, 2015
    Oddometer:
    57
    Location:
    Moora
    Function creates it's own form. It's looking great!
    #36
  17. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    I put on new tires and forks from another 3k mile donor bike. I added fork gaiters and made fork tube covers for the top. After putting the tires on, I was kind of shocked at the handling...it seemed heavy and sluggish. After riding it a lot more I figured out the tires were fine and the new forks were in superb condition and I put in 15 Weight fork oil which I really like for the feel. To sum it all up, the newer fork legs, 15W oil and new tires were actually so much better I was missing all the "road" feel of the clapped out 80k forks and old tires/wheel bearings. Overall it was much tighter and smoother riding with way less front-end dive in braking- Plush.
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    #37
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  18. Scott in Missouri

    Scott in Missouri Been here awhile

    Joined:
    Feb 4, 2008
    Oddometer:
    284
    Later I mounted an old fairing a friend gave me off a Harley. It looked like the fairing would fit perfect if it was a little higher so I drilled the headlight mount all the way through the bottom triple tree...then put the steel mount I made on top and the headlight fit right inside the hole perfect. Coincidentally, the headlight was off a Harley also. A few cuts/drilled holes and the fairing fit nicely and protected the GPS and dash. Unfortunately I had to drop the forks to drill the holes. Just need to paint a last couple pieces black and it will be finished.
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    #38
  19. Scott in Missouri

    Scott in Missouri Been here awhile

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    Feb 4, 2008
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    Fits nice, but the hand guards had to go since they looked odd.
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    #39
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  20. Jim Day

    Jim Day full manic mechanic

    Joined:
    Mar 14, 2012
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    5,136
    Location:
    So. Cal.
    #40