Topic: Chopper reincarnation (Read 1912 times)

Puzzled · « **on:** July 31, 2010, 09:36:25 pm »

My chopper has been sitting for a few years now. Most years I at least take it out a few times, not this past year. The bike was sitting in the front of the garge with the tires near flat. I have had it on a battery tender the entire time. The chrome look like crap as most of it is either pitting or has turned gold. The paint is fair as it has its fair share of chips and a few cracks here and there.

The bike has no value with the current market and even less value in the state that it is in. I had contemplated tearing the bike apart and either parting it out or using the parts and build my next project. I still like the bike so I decided to freshen it up some. The paint will get me through another year so I won't touch it. The chrome has to be stripped and replated. That is where I'll start.

The reincarnation of my 2003 10 up Chopper.

Onto the lift.

Puzzled · « **Reply #1 on:** July 31, 2010, 09:37:06 pm »

The overall state of the parts.

Puzzled · « **Reply #2 on:** July 31, 2010, 09:37:44 pm »

Puzzled · « **Reply #3 on:** July 31, 2010, 09:38:11 pm »

Most of the parts going to the platers.

Puzzled · « **Reply #4 on:** July 31, 2010, 09:38:47 pm »

Back from chrome. The plater I have been using for the last year or so has been spot on with his work. Everything comes with a one year warranty.

Puzzled · « **Reply #5 on:** July 31, 2010, 09:41:08 pm »

Gaskets and parts.

Puzzled · « **Reply #6 on:** July 31, 2010, 09:43:05 pm »

The mirror heads I'll rob from the stalks.

The headlight that I run a PIAA bulb in.

Some new Springer springs.

rocker bolts which I ended up not using.

Puzzled · « **Reply #7 on:** July 31, 2010, 09:44:33 pm »

Having only ever been inside of a Twin Cam I was a little surprised when I pulled the cam cover and out came the cams! Uh oh.

Out came the manual and I lined everything back up.

Puzzled · « **Reply #8 on:** July 31, 2010, 09:46:21 pm »

The backside of the cam cover. A few new seals and bushings and all is fresh.

The ignition cavity.

Puzzled · « **Reply #9 on:** July 31, 2010, 09:49:14 pm »

...and wouldn't you know it I broke a F'ing bolt in my freshly plated cover.

There isn't much I left unturned.

Puzzled · « **Reply #10 on:** July 31, 2010, 09:50:41 pm »

Some pics of the stuff going back together.

Puzzled · « **Reply #11 on:** July 31, 2010, 09:51:34 pm »

I had a second set of forward controls so I just replaced what was on the bike as opposed to haveing the original controls re-plated.

Puzzled · « **Reply #12 on:** July 31, 2010, 09:52:15 pm »

The left sid of the steering neck, so what right?! This is where my VIN is suppose to be. I never affixed it to the bike. It has been under the seat since day one.

A hammer, my favorite tool.

All legal like now!

Puzzled · « **Reply #13 on:** July 31, 2010, 09:54:26 pm »

This is a problem. Ok you actually can't see it but there is one that I believe is going on inside of that fender. My bike started puking a lot of oil out of the head breathers awhile back. I tried a few things to no avail. Changing the oil one day I heard something clanking around in my oil tank. I suspect that it is the return line inside of the tank, it broke loose. This would explain my oil puking problem. The oil can't return thus building up in the line and motor.

Puzzled · « **Reply #14 on:** July 31, 2010, 09:55:07 pm »

The proposed fix. Since I don't want to cut a hole in the tank to weld a new bung in and mess up the paint that leaves me with very few options. I searched for a pipe thread nut-sert to no avail (I didn't look all that hard). So my plan of attack was to install a nut-sert than drill and tap it for a pipe thread fitting.

I applied a generous amount of sealant around the nut-sert prior to squeezing it tight.

Puzzled · « **Reply #15 on:** July 31, 2010, 09:55:42 pm »

Here is my temp fix. If this works as I hope it should I'll work on the appearance part next. Since the Nut-sert threads are deep a standard chrome MC fitting would not work as the nipple was to short. I used a brass nipple and threaded it into the Nut-sert than the fitting onto it. Not pretty but functional.

Puzzled · « **Reply #16 on:** July 31, 2010, 09:56:19 pm »

I came across this while taking the springer apart. I ordered a OEM replacement set of bolts but they did not match my dimensions. A fellow forum member looked into a replacement set of bolt for me from the original manufacture of the original front end and that man must have been smoking dope when he quoted a price. Needless to say I'll make my own.

The replacement bolt and axle nuts installed.

Puzzled · « **Reply #17 on:** July 31, 2010, 09:57:09 pm »

For some odd reason I got this notion that I wanted a 26" wheel on the front of the bike. Well the manufacture went out of business four years ago. I had no desire to purchase a new set of wheels so the search for someone to build me a wheel was on. As I posted in another thread Greg from Thomason is going to take care of this for me.

This is a pic of the blank style that is going to be used.

Puzzled · « **Reply #18 on:** July 31, 2010, 09:57:56 pm »

The tire showed up, dam that is a big tire!

Puzzled · « **Reply #19 on:** July 31, 2010, 09:58:27 pm »

The tire is run flat of sorts, interesting.

Puzzled · « **Reply #20 on:** July 31, 2010, 09:59:23 pm »

I flipped my license plate around to the horizontal position as most states are now wanting them this way. I don't need to give the man a reason to pull me over as I'm sure he'll find another reason!

Now from close behind the visibility is, well, minimal. From 8'-10' back it isn't to bad. Should I ever build another fender I will incorporate a plate and taillight into it, something with some visibility. I'd rather not get run over just for vanity!

Puzzled · « **Reply #21 on:** July 31, 2010, 10:00:01 pm »

I fired the bike up a few days ago. I can not believe the bike fired right up. It hasn't run for over a year. Plus I installed the cam and valve train!

Oh where I was going with this.... the clutch. man was it nice to not hear the ol' BDL rattle. The new clutch is sweet. I may actually be able to ride in traffic without whining like a little girl.

My hand use to hurt big time after a day of riding, dam age catching up with me.

Puzzled · « **Reply #22 on:** July 31, 2010, 10:01:24 pm »

My backyard method of collapsing the springs enough to get the top nuts on.

To get this far I had to make a new center bolt for the springs as the original one snapped off inside of the top nut. Since there was a piece of the bolt in the nut I drilled it out than tapped the nut to accept a Heli-coil. Stainless is vicious!

Puzzled · « **Reply #23 on:** July 31, 2010, 10:02:09 pm »

I spoke to the wheel blank manufacture today and it looks like there will be no way in hell I'll have my 26" wheel in time for Daytona. Maybe I should just go 30"?!

Puzzled · « **Reply #24 on:** July 31, 2010, 10:04:00 pm »

I took the bike out for a ride Monday in the 30* weather. There was no precipitation and the roads were dry, albeit cold. The bike feels good, dare I say it, better than before. I'll admit I have learned a lot since first building this bike. So I would imagine that during the re-assembly this time I did things slightly better than the first time around.

I had either clutch slip or tire slip when I rolled on the throttle hard. I couldn't tell which one was the culprit. I tightened the clutch just a little bit more when I returned back to the shop. I'll see what it likes when I hit Daytona.

The front end felt a little stiff. I did cycle the front end through its range of movement prior to installing the springs so I know I don't have anything binding. It may just be the new springs.

I was leary of my cam and valve train install initially however now I'm confident I installed everything correctly. The bike fires up real easy and runs just as good. :nice:

If there were a down side to my ride it would have to be I saw a little weep-age at the lowest corner of each rocker box. That is my bad as I re-used the rocker box gaskets after a failed attempt at ordering replacement gaskets. :slap: Since than I ordered direct replacement TP gaskets to take with me to Florida. I did twist the rocker box bolts another degree or two just for grins.

Feeling pretty good about the bike sans the lack of my 26" front wheel

I ordered up a few do-dads such as a wire retainer and handlebar spacers for it. I'm treating it to a little dessert!

Puzzled · « **Reply #25 on:** July 31, 2010, 10:04:44 pm »

Puzzled · « **Reply #26 on:** July 31, 2010, 10:05:29 pm »

Greg cut the other side today. :nice:

Puzzled · « **Reply #27 on:** July 31, 2010, 10:06:11 pm »

26" next to a 21"!

The wheel is now completely cut. Greg will get it off to me Monday at which time I'll fit the hub than off to chrome it goes.

Puzzled · « **Reply #28 on:** July 31, 2010, 10:06:52 pm »

Puzzled · « **Reply #29 on:** July 31, 2010, 10:08:02 pm »

26" Wheel weight

26" tire weight

21" wheel and tire weight

26" wheel and tire weight

Puzzled · « **Reply #30 on:** July 31, 2010, 10:08:51 pm »

Puzzled · « **Reply #31 on:** July 31, 2010, 10:18:33 pm »

Puzzled · « **Reply #32 on:** July 31, 2010, 10:19:16 pm »

Puzzled · « **Reply #33 on:** July 31, 2010, 10:22:04 pm »

Puzzled · « **Reply #34 on:** July 31, 2010, 10:23:25 pm »

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