Giving the old Sportster an heart-transplant (and where will it end...?)

Discussion in 'Some Assembly Required' started by norseXL, Feb 11, 2018.

  1. norseXL

    norseXL Northman

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    Hi, I got those boxes for free and they are from a water cooled 1200 gs so have the smaller box for exhaust on the right side, I then bought the docking frames for them.

    Then I fabbed up four counter sunk studs of stainless 20mm dia if I recall and four sleeves to fit over them. I also made four thick plastic washers to put on the stubs before sliding the sleeves over the studs.
    I then hung up the boxes mounted to the docking frames so they was placed where I wanted them to sit.
    I then welded 12mm stainless rod between the sleeves and the docking frames.
    #81
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  2. norseXL

    norseXL Northman

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    #82
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  3. norseXL

    norseXL Northman

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    #83
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  4. norseXL

    norseXL Northman

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    #84
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  5. norseXL

    norseXL Northman

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    #85
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  6. norseXL

    norseXL Northman

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    #86
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  7. norseXL

    norseXL Northman

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    #87
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  8. norseXL

    norseXL Northman

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    This strut was to weak, it was flexing, I braced it later

    upload_2018-10-16_19-31-46.jpeg upload_2018-10-16_19-31-46.jpeg
    #88
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  9. norseXL

    norseXL Northman

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    The front lower points I used rubber bump stops I cut the rubber flat on,they were the conical type cars use.
    Bad pic from my dark garage...

    [​IMG][​IMG]
    #89
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  10. norseXL

    norseXL Northman

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    I also made a cross brace at the rear, just like the GS uses, rigidity of the whole unit as a box is important so I used big dia stainless tube.
    I can easily take the whole unit of and only the four stainless studs remain...
    #90
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  11. norseXL

    norseXL Northman

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    .
    .[​IMG]
    #91
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  12. norseXL

    norseXL Northman

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    I did only have a MIG welder and no stainless weld wire, to avoid rust I just bronze brazed over the welds.
    It has now been misstreated over two summers with two trips to the alps from Norway and been working great with wery heavy loads. I plan of reinforce the mounting points of the studs by some bracing innside the fender just for peace of mind, I realy load them some time (beer runs over to Sweden comes to mind)
    #92
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  13. norseXL

    norseXL Northman

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    If you want me to take some more pics of some details just say and I will do tomorrow under better lights
    #93
  14. rodteague

    rodteague Enjoying the ride

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    Perfect; thank you. Just wanted to see how you fabbed up your mount points. Good job BTW:beer
    #94
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  15. madrider5150

    madrider5150 Riding somewhere

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    How are your ohlins holding up? Must be worth it if you're going upgrade/update them..
    I looked into the 16" for the xr and they will bolt right up to the 2000 they said, so I'd guess at least 98-03 fits

    Sent from my Moto G (4) using Tapatalk
    #95
  16. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    Wow, great fab on the GSA panniers! :thumb
    #96
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  17. norseXL

    norseXL Northman

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    They are ok, but I want full adjustability and hydraulic pre load adjust. Spanners suck for quick work when tossing the bags in a hotel and do day trips
    #97
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  18. norseXL

    norseXL Northman

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    Winter is coming...!
    ...and so is parts.
    Rear wheel from Duc 696 is one thing to be fitted...

    .
    [​IMG]
    #98
  19. norseXL

    norseXL Northman

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    Mailman came with a big packet friday, bought a 3D printer. Now busy playing around in Fusion 360 trying to learn the basics, thank Odin for YouTube.
    Tried to make a new cover for the ignition module as a start, will propably use it for caliper bracket mock-ups too...
    .
    upload_2018-11-4_13-14-53.png
    .
    upload_2018-11-4_13-15-26.png upload_2018-11-4_13-14-53.png upload_2018-11-4_13-15-26.png
    #99
  20. norseXL

    norseXL Northman

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    Well damned!
    Seems like that overly biggly sprocket carriers that Ducati uses made the wheel to wide even for my JMC rear fork.
    It did fit but the offset to the left needed was just to much...

    ...so I bought a tuber Buell wheel on the bay-of-e, seems a cush-drive is not in my future, but a 17" WILL be.
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