Not your Typical Harley Softail

Discussion in 'Some Assembly Required' started by Bevelheadmhr, Dec 21, 2017.

  1. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    I have access to a bead blaster, but not a tumbler. Once the bracing is finished, I'll ask around and decide what finish its having. There's no rush, as if its going on my Evo softail, it wont be until next winter.
    #61
  2. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Had an interesting morning, weighing the XL1250 and a near standard XL883 yesterday, using the calibrated scales built into the brake testing machine used for the annual test with have here in the UK.

    Wasn't sure how accurate the method would be, as it tests one wheel at a time, but the numbers we got from the near standard bike were close to its official weight (485lbs for a 1991 XL883).

    The XL1250 would be lighter of course, but how much?

    It weighed in at 400 lbs with only a little fuel in the tank. Not bad at all. Still hasn't been set up on the dyno due to lack of time, but it sounds ok being run up and down the road.. here it is if you want to hear it..

    #62
  3. MATTY

    MATTY BORDER RAIDER

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    I enjoy reading these posts well done on reduction of weight i am a big believer in losing every oz you can, its clearly paid off there.
    Losing just a couple of pounds is often not that simple to achieve so good job there and it sounds great.
    #63
  4. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Its a pity I haven't got the XL 1250 filmed on the dyno yet, be interesting to see what it makes given the motor still has the OE 883 cams. But there is a good reason for the delay, as Sam West the Dyno operator also races at a high level, and is away having just competed in the North West 200 and is racing at the TT next.

    On a different note, finally decided on the bracing for the alloy swing arm, keeping it simple and following the style of the original. Getting hold of the appropriate gauge tubing (at the right price) proved tricky, so instead I've ordered solid alloy bar which is cheaper, and when it arrives, I'll drill it to lose weight before its bent into shape and welded in place. Then after hours of prep to remove all its blemishes, the arm will be ceramically anodised, as its a very tough finish which doesn't alter the dimensions of the piece. Finally a new battery cage will be made to take a lithium battery … another 12 lbs saved. But it wont be fitted to the bike until next winter, while in the meantime I've got my Ironhead Norley to upgrade next.
    #64
    invisa-bill likes this.
  5. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    My mates XL1250 finally had its first run on the dyno today. Its running way too rich, and with standard cams and rejetted OE carb, we weren't expecting huge power numbers. Although it was built for low end torque over top end HP in any case.

    Despite running rich, it made decent power, with a smooth graph, no sudden dips in HP as the revs climbed. With leaner jetting should make more a bit more HP.
    What did it make? You'll have to watch it running on the dyno to find out ..
    https://youtu.be/LmodhLHAK7c
    #65
    invisa-bill and Richy like this.
  6. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Finally got around to working on the alloy swingarm again. It needed two underbraces to replicate those of the original steel arm. But that proved to be difficult as alloy bar cant be so easily bent and manipulated as steel. So after a couple of false starts, I came up with a final design. I bought 1m of 30mm alloy bar, cut it in half, then line drilled them (had to use a friends 1940's Capstan lathe, as ours isn't big enough. I left the last few inches of one end solid. This would be the lower end which was machined down to a 20mm flat, so it could be welded to the lower part of the side plates of the arm. The other hollow end was profiled on the miller to fit the underside of the two arms. That done, just had to take it to Geoff the welder who welded them into place.

    Pity I forgot about the need for a bracket on one brace to hold the brake torque arm, but it'll be added when I get time.

    Next task is to make a wheel spindle, not sure yet what to use.. EN24 or Stainless steel.. Ti would be light, but I hear its banned from being used in race bikes for good reason, so probably best to stick with steel. Also need to make a battery box for the lithium battery its getting.. still need to buy a suitable one of those. Then finally have to decide on the finish.. either polish it or polish it and have it ceramically coated.

    Total weight of the arm is 17lbs with the temporary thread bar 'spindle'.. about half of the original steel version.

    swingarmweldandlesbike 052.JPG 008.JPG
    #66
  7. MGN54

    MGN54 Been here awhile

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    Wow! Beautiful work!
    #67
  8. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    I wanted to use 3/4 inch EN24 steel to make a wheel spindle, but I'd have to order 3m of it as my local workshop doesn't stock much imperial sizes anymore. Instead I was given 18 inches of 20mm EN24T, which will need to be machined down to 3/4 inch. Also had to buy a couple of stainless 3/4 UNF nuts … which cost an eye watering £6 each.

    BTW here's a video of the work we did on the swingarm
    #68
  9. IronButt70

    IronButt70 You don't have to be crazy to do this but it helps

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    https://www.merchmotors.com/
    Merch is building stuff again somewhere in Canada. Hope this link will help you in some way. Didn’t read the whole thread so sorry if this was posted before.
    #69
  10. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Just seen this, thanks for the link, looks to be a small operation for now, hope it goes well for them. I believe the original company was run into the ground by a bunch of crooks after the original owner sold the company.
    #70