Differences

This shows you the differences between two versions of the page.

--- techtalk:ref:body30c [2019/06/17 00:22]
hippysmack [1986 to 2003 forward controls modified to fit a 1980 frame]
+++ techtalk:ref:body30c [2022/03/09 04:55]
ixl2relax [REF: Body Parts - Sub-01C]
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
-====== REF: Body Parts - Sub-01C ======
+====== REF: Body Parts - Sub-30C ======
 ====== 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)) \\
@@ Line 15: / Line 15: @@
 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>
-|Re-locating the left peg position, see red circle ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) ((http://xlforum.net/forums/showthread.php?t=717997))|Right side Assembly ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344)) ((http://xlforum.net/forums/showthread.php?t=717997))|
+|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:ih:body:forward_mods_11_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_1_by_ironmick.jpg?direct&300|}}|
 |{{:techtalk:ref:body:forward_mods_14_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_13_by_ironmick.jpg?direct&300|}}|
@@ Line 40: / Line 44: @@
 |{{: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. \\
@@ Line 52: / Line 58: @@
 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))|
@@ Line 66: / Line 81: @@
 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. \\
-Later on, a newer style rear brake master cylinder replaced the '80 version to eliminate this 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|}}|
-|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|}}|
-|Left shift lever ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|Shift lever ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|
-|{{:techtalk:ih:body:forward_mods_8_by_ironmick.jpg?direct&250|}}|{{:techtalk:ih:body:forward_mods_9_by_ironmick.jpg?direct&250|}}|
-|Left side shift pedal. ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|
-|{{:techtalk:ih:body:forward_mods_7_by_ironmick.jpg?direct&300|}}|
-|Shift Pedal ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|Brake pedal. ((photo by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))|
-|{{:techtalk:ih:body:forward_mods_10_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_4_by_ironmick.jpg?direct&300|}}|
-|Pedal ((photos by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))||
-|{{:techtalk:ih:body:forward_mods_5_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_6_by_ironmick.jpg?direct&300|}}|
-|Brake lever mods ((photos by IronMick of the XLFORUM® http://xlforum.net/forums/showthread.php?p=2726344#post2726344))||
-|{{:techtalk:ih:body:forward_mods_3_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:body:forward_mods_2_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|}}|

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