Engineman makes bad decisions: An Electra Glide story

Discussion in 'Some Assembly Required' started by engineman, Jan 8, 2019.

  1. StittWall

    StittWall Been here awhile

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    Looks like some nice progress. As to the tourpak I bought this from a place in Canada.
    I had it on my local craigslist as I went another direction with my road glide. The mount is a q/r for 2009 and newer. It works fine, real close to HD , most can't tell difference. 20191207_145228.jpg 20191207_145228.jpg 20191207_150023.jpg
    #81
  2. StittWall

    StittWall Been here awhile

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    Nastyhog was the retailer. Led sidelights standard.
    #82
  3. engineman

    engineman Been here awhile Supporter

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    I have to admit, on a smooth, straight stretch of pavement the Glide is a nice bike to ride. Around here though, even when I am on pavement it is not smooth. Frost heaves, potholes and scattered gravel upset the bike. On the rare occasion I can find a curvy road you can definitely feel the chassis flexing under you.
    #83
  4. engineman

    engineman Been here awhile Supporter

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    That does look like a very good option. If I have trouble selling it without the pack, I might give that a shot
    #84
  5. StittWall

    StittWall Been here awhile

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    If you want a used one, let me know, not sure what shipping would be, I'm in W. PA
    #85
  6. Andyvh1959

    Andyvh1959 Cheesehead Klompen Supporter

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    Da frozen tundra eh? 1.5 mile west of Lambeau
    I have not ridden a HD FLH full dresser since that demo ride event back in 06. The new chassis FLH is supposed to be vastly better than the older chassis in handling and tracking. All I remember is the older FLH felt way too uncertain even at speeds from 35 to 70 mph. I've been used to riding solid feeling easy handling BMW flat twins since the mid-90s so my opinion was certainly slanted toward a light weight solid feeling chassis. I was pretty critical of the HD FLH back then. I've also not ridden a FLH of that vintage with the police bracket on the frame. Other MSF instructors I've worked with that had the police bracket on their FLH chassis said it made a big difference.
    #86
  7. engineman

    engineman Been here awhile Supporter

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    Time to talk about the tank. Hold on, things are going to get bumpy

    Originally I had decided to ignore the dent in the tank, however it wasn't long before the paint flaked off and it started to rust

    20190624_202500.jpg


    I hit it with the die grinder and cleaned it up some

    20190629_120628.jpg

    This is where all the pros out there will be thinking "and then he pulled the dent" but I didn't. My paintless dent puller wouldn't touch it and I don't have a stud welder. I do have a shit load of other welders though and in retrospect, I should have MIG welded a screw to the center of the dent and used that to pull it out. I ended up puttying it as is. It's about 1/4" thick in the center but it's not that big around so I think it will hold fine. There's no flex in the metal here

    This is an "in process" picture. I did get it pretty much perfectly smooth eventually with another hundred or so hours of sanding. I also found another dent that I didn't notice at first and filled it too.

    20190630_134244.jpg

    You might notice that I'm working on the tank with it mounted to the bike. For those of you who might try this someday, don't. It's stupid and I don't know why I didn't remove it from the bike, it would have been a hell of a lot easier. It was a lot of work to mask the bike when I started spraying paint.

    I had to be careful here to not sand into the pinstriping

    After a ton of masking work I primed and basecoated the area around where the dent was and then (more sanding) cleared the whole tank.

    It actually looked great right up until I started using the polishing compound.


    20190912_175114.jpg

    Pinholes everywhere in the clearcoat. :doh:baldy

    I think they call this solvent pop? I'm 90% sure it's because I didn't wait long enough between coats of clear coat

    Tried sanding it out but the issue is the decals and pinstripes under the original clearcoat

    Attached Files:

    #87
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  8. engineman

    engineman Been here awhile Supporter

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    When we last left the story, I had F'd up the clearcoat on the tank. The point of this whole exercise was to get better at bodywork and hopefully make a few bucks selling this bike so it wasn't going to do leaving it as is.

    Another view of the tank, this time removed from the bike

    20200309_174708.jpg

    The pinstripe and the decals are under the original Harley clearcoat. You can see in the upper right corner that I had already sanded into the pinstripes on the original repair. I started trying to sand through my clear without hitting the decals but it wasn't working.

    I watched way too many episodes of "biker build off" back in the day (holy crap that show was almost 20 years ago already!) so my overconfidence level was pretty high that I could still fix this

    I'm sure the slow, patient and careful approach would have been best but I have poor impulse control and literally a drawer full of angle grinders so this was going back to bare metal

    The grinders were actually the last resort. If there is one thing that Harley does extremely well it is paint. I couldn't believe how hard it was to get off. Chemical strippers worked on the paint and clear that I applied but had no effect on the factory paint. My HF sandblaster made some impression but 20 minutes of blasting only cleared a dollar bill sized spot. What finally worked was a stiff wire knot wheel on a 4.5 grinder. Took a while and my lungs are now infused with the essence of Milwaukee's finest paint but I got it down to metal

    20200315_145713.jpg

    Next step was to dig out the filler I installed before and make another attempt at fixing the dent right

    20200316_174938.jpg

    Attachment point for my home made dent puller

    20200316_180525.jpg

    Dent pulled and bolt cut off. I should have used a little less weld but I think it will be ok

    20200316_180907.jpg
    #88
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  9. StittWall

    StittWall Been here awhile

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    Wow, I was wondering how you would correct the clearcoat. I would have never guessed this was how!!!!
    You got my attention! Looking forward to seeing the rest
    #89
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  10. xr-nut

    xr-nut Out Ridin' Around

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    who gives a crap?
    No one else hit the like button on the above post about the tank, guess I will. I admire your tenacity!
    #90
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  11. engineman

    engineman Been here awhile Supporter

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    Still too cold to apply filler or paint so I'm going to work on the front fender.

    If you remember from above, it had a shallow dent that I mostly pulled with a paintless dent puller. It was better but still not good enough so might as well fix it too

    Didn't strip the entire fender, just got rid of the paint where it needed a repair and the decals and pinstripes under the clear

    20200315_154809.jpg

    Should be able to blend it pretty smooth. Cant really feel the transition with bare fingers

    20200315_155025.jpg

    Problem with this section where the dent was is that there is now a pretty big "oil can" centered where I marked the circles

    20200315_155238.jpg

    Used a big 3/4 drive socket as a die on the back, heated a couple of spots to dull red with the torch then gave it a quick smack with the ball end of a hammer. Pulled the metal back tight, no more oil can.

    20200316_173741.jpg

    That whole section is slightly low now so I should be able to lay some filler over it and get it nice and straight again
    #91
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  12. xr-nut

    xr-nut Out Ridin' Around

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    who gives a crap?
    I am not a body man, but I do pretend to be one in my job sometimes. If I were you, I would go ahead and strip the fender all the way now. I am not sure you can hide that seam. If you "can't really feel" it, it has been my experience it will show in the paint. Just my 2cents and likely not even worth that!
    #92
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  13. engineman

    engineman Been here awhile Supporter

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    You're probably right. Wont be that much more work. I think you caught me getting lazy
    #93
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  14. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    There is no problem blending it if you feather it well. If you have a sharp edge visually, it isn't feathered enough, even if you can not feel it.
    #94
  15. 306dad

    306dad Been here awhile

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    Looking awesome
    #95
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  16. StittWall

    StittWall Been here awhile

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    Its going to be so nice.......you'll keep it!
    #96
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  17. jules083

    jules083 Long timer Supporter

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    I have a tourpack for your bike in Eastern Ohio. I bought it used for $300 and would sell it for that if you're interested. No damage, has a luggage rack on top and holes for Ultra Classic speakers but no speakers themselves.


    Just read your Ride Report from Florida, looks like a great trip! I'm hoping to take my son on a few like that when he's older.
    #97
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  18. engineman

    engineman Been here awhile Supporter

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    Back at it-

    got the tank dent filled and the fender nice and straight. Since the metal in the dented area had taken so much abuse I actually used JB weld for the majority of the filling, just a skim coat of body filler over the top of it.

    20200401_175518.jpg

    Found quite a few other dents in the fender that I hadn't noticed were there


    20200401_175120.jpg

    Had some help in the shop. She's actually taking to this. Pretty artsy and perfectionist which translates well to body work

    20200401_175127.jpg
    #98
  19. jules083

    jules083 Long timer Supporter

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    Looking good so far! At least with the corona going on we all have a bit of time to get projects done.



    I think women are naturally better at stuff like that. I'm a pipe welder, and most female welders I know are slower at welding but the finished product is better. Not all of course, but as an overall generalization.
    #99
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  20. engineman

    engineman Been here awhile Supporter

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    Getting ready for primer

    20200403_184406.jpg

    I'm going to be spraying an epoxy primer for bare metal applications, then I'm planning on a couple coats of urethane primer surfacer to sand smooth then a single stage urethane basecoat.

    I'm getting all my paint supplies from Eastwood company. I'm not enough of a pro to be able to speak to the quality or value of their paint but they have a ton of very good DIY videos to help people like me get started and I like to support that kind of behavior by a company.

    20200403_190604.jpg

    Mixed and sprayed the epoxy primer. Came out ok. I feel better about my gun setup this time (thanks to one of the aforementioned videos). I did try laying it on too heavy for the first coat and got some runs I'm going to have to fix but overall looks ok.

    20200404_174922.jpg


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