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techtalk:ref:body30c [2019/06/16 20:26] hippysmack created |
techtalk:ref:body30c [2024/01/09 20:32] (current) hippysmack |
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| - | ====== 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® ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/99656-forward-controls-85xlh1000#post2068972)) \\ | ||
| + | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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® https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))|Right side Assembly ((photo by IronMick of the XLFORUM® https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))|Right side nut and E-clip ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/93684-just-a-update-on-my-79-project-opinion-poll-pics/page2?highlight=forwards#post2167215)) \\ | ||
| + | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) \\ | ||
| + | |||
| + | |Brake stop band-aid. ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997)) |Newer rear brake master cylinder. ((photo by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/89445-86-to-03-hd-forward-controls-modified-to-fit-1980?t=717997))| | ||
| + | |{{:techtalk:ref:body:forward_mods_23_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:body:forward_mods_24_by_ironmick.jpg?direct&300|}}| | ||
| + | |||
| + | |||
| + | \\ | ||
