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techtalk:ref:body30c [2019/06/16 20:26]
hippysmack created
techtalk:ref:body30c [2022/03/09 04:53]
ixl2relax ↷ Page name changed from techtalk:ref:body01c to techtalk:ref:body30c
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 [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]] [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]]
 ====== REF: Body Parts - Sub-01C ====== ====== REF: Body Parts - Sub-01C ======
 +====== 1986 to 2003 forward controls modified to fit a 1980 frame  ======
 +Article by IronMick of the XLFORUM® ((http://​xlforum.net/​forums/​showthread.php?​p=2726344#​post2726344)) \\ 
 +In the event that you cannot find forward controls specifically for your year model, you can find something that you can modify to work. \\
 +However, working well can be a challenge. \\
 +Below are some mods made to a 1980 XLH.
 +
 +Shift side should be no problem. Brake side would require some work.
 +<​blockquote>​When I looked at an 86 to 03 custom Sportster it occurred to me that I could make the forwards work on my 1980. ((IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) \\
 +It was looking at the brake side that convinced me - the way they fit between the case and the exhaust. \\
 +(and the similar rear brake master cylinder) \\
 +I found a new set of after market 86-03 HD style forwards (brand unknown) on eBay for about $220. \\
 +Examining the parts I saw that I needed to drill 1" diameter holes in the lower front engine mounts. \\
 +After much discussion on XLForum and consulting with my indie mechanic, I decided to do it. \\
 +I let the indie drill the holes as my small drill press would not handle a 1" bit. \\
 +The 1/8" steel mount with that large of a bit requires a bigger drill press. \\
 +Next was measuring and manufacturing the spacers. \\
 +Also tedious requiring precision measuring machine shop work. The measuring was difficult because of the location on the bike. \\
 +I did not modify the parts much. Mostly I modified the bike parts so the controls would fit. \\
 +Overall it was quite expensive. \\
 +</​blockquote>​
 +
 +|Left side assembly ((photo by IronMick of the XLFORUM® ((http://​xlforum.net/​forums/​showthread.php?​t=717997))|Right side Assembly ((photo by IronMick of the XLFORUM® ((http://​xlforum.net/​forums/​showthread.php?​t=717997))|
 +|{{:​techtalk:​ref:​body:​forward_mods_14_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_13_by_ironmick.jpg?​direct&​300|}}|
 +
 +
 +\\
 +  * **Right Side Parts**: (note spacer between large washer and mount)
 +    * Threads on Part = 1.08"
 +    * Spacer = 0.32"
 +    * Flat washer = 0.17"
 +    * Engine mounting plate = 0.17"
 +    * Nut = 0.42"
 +    * E-clip
 +  * **Left Side Parts**: (no spacer needed)
 +    * Thread Length on part = 0.69"
 +    * Flat washer 0.17"
 +    * Engine Mounting plate 0.17"
 +    * Nut 0.35"
 +    * E-clip
 +
 +|  Motor mounts and parts. ((photos by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) ​ ||
 +|{{:​techtalk:​ref:​body:​forward_mods_15_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_16_by_ironmick.jpg?​direct&​300|}}|
 +
 +Template for lower front motor mount hole to be drilled: \\
 +{{:​techtalk:​ref:​body:​forward_mods_25_by_ironmick.jpg?​direct&​300|}} ((drawing by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997))
 +
 +<​blockquote>​To restore the strength lost by drilling the hole, the largest 1" ID steel washer that would not be too large OD was used. \\
 +This same thickness as the engine mounts themselves and installed directly against the engine mounts on the outside. \\
 +The most difficult part was the measuring. I had to determine the exact center for the hole on the right side. \\
 +This way the brake rod would be level both horizontally and vertically, and the mounting hardware would fit evenly between the case and exhaust. \\
 +Then the left side was drilled exactly the same as the right. And I had to measure for a spacer for the right side. \\
 +This all required a couple or a few hours lying on the shop floor looking up at the bike, getting a stiff neck, and measuring, measuring, measuring. \\
 +The right side required a spacer which had to fit on over the threads. \\
 +So I had it cut from a nut. \\
 +Then I also had a nut trimmed so that it would use up all of the threads on the mounting hardware, and allow a close fit of the E-clip. \\
 +More precision measuring. \\
 +</​blockquote>​
 +
 +The drilled hole in the motor mount offset will clear the fit with the exhaust. \\
 +Measuring for that hole took the most time. \\
 +It's an awkward place to measure. \\
 +You have to take into account the odd shape of the front of the right side case and gearcase cover, as well as the exhaust pipe. \\
 +After the right side was measured, the left side was made exactly the same. \\
 +However, all front exhaust pipes do not have the same bends. ​
 +These are OEM pipes with the crossover. \\
 +It might be a good idea to fabricate a mount from thick cardboard, cut the hole, and check to see if it is good. \\
 +
 +|Right side spacer (partly hidden by oil line) ((photo by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997))|Right side nut and E-clip ((photo by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997))|
 +|{{:​techtalk:​ref:​body:​forward_mods_17_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_18_by_ironmick.jpg?​direct&​200|}}|
 +
 +The left side was easier as it did not need any spacers. \\
 +But, as on the right side, a 1" ID nut had to be trimmed so that it would use up all of the threads on the mounting hardware. \\
 +And it would allow a close fit of the E-clip. More precision measuring. \\
 +
 +|  Left side nut and E-clip. ((photos by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) ​ ||
 +|{{:​techtalk:​ref:​body:​forward_mods_19_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_20_by_ironmick.jpg?​direct&​200|}}|
 +
 +The trimming of the nuts and the making of the spacer were done at a local machine shop - cost about $60.00. \\
 +The shift lever that came with the kit was not usable here. \\
 +So, some length was trimmed and the hole drilled from a 1998 Sportster lever. \\
 +
 +The 1980 rear brake master cylinder does not have a mechanism to hold the brake rod in. \\
 +So the brake rod just falls out. \\
 +With mid-controls this is prevented by the brake stop. \\
 +To solve this a hose clamp was attach to a 3/4" length of 1/2" copper pipe to the front exhaust pipe as a band-aid. \\
 +The big hole in the brake stop below goes over the footpeg stud and the adjustable screw sets the foot pedal height. \\
 +There is no part number for the brake stop as HD never made them as a separate part. \\
 +They were a welded-on part of the muffler. \\
 +You can / could order them from the Cycle Shack website. \\
 +
 +|  Rear Brake Stop for mid-controls. ((photos by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) ​ ||
 +|{{:​techtalk:​ref:​body:​forward_mods_21_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_22_by_ironmick.jpg?​direct&​300|}}|
 +
 +A better idea might be to use a later model rear brake master cylinder. \\
 +It has a different design which holds the brake rod in with a snap ring (circlip). \\
 +It also is easier to repair as it uses a one-piece kit. There have been lots of these on eBay in the past.
 +
 +With 86 to 03 forwards, the master cylinder stays in the stock location on the sprocket cover. ((IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=2871067&​highlight=forwards#​post2871067)) \\
 +The M/C pic below was taken before realizing that the fluted connection would not work. \\
 +Later a brake line was fabricated with a banjo fitting for this. ((photos by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) ​ \\
 +
 +|Brake stop band-aid. ((photo by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997)) |Newer rear brake master cylinder. ((photo by IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=717997))|
 +|{{:​techtalk:​ref:​body:​forward_mods_23_by_ironmick.jpg?​direct&​300|}}|{{:​techtalk:​ref:​body:​forward_mods_24_by_ironmick.jpg?​direct&​300|}}|
 +
 +
 +\\