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Bandit, when we met, on your way to Sturgis, I told you about this project and after your encouragement have tried to chronicle this escapade. So here goes and thanks.
Projects have a way of growing way past their original intention. This one is no different. Originally meant to be a project with my kids on a limited budget, this has turned into the most expensive Sportster project on the planet with my kids, or so it seems. Thru it all we are having fun and the kids enjoy hanging with Dad despite his constant deer-in-the-headlights, perplexed and confused facial expressions. You just can’t fool kids.
The Sporty project started with the purchase of this ‘75 Ironhead Sportster. It ran, sort of, but who cared, it was going to be rebuilt anyway. It was only firing on one cylinder, third gear would pop out and it needed to be jumped to fire it. Thirty years of oil, grease and dirt couldn’t hide my excitement as I rolled it out for my family’s inspection. The giggles followed by the smartass comments did nothing to dull my smile, as I could envision what would be, not what was. My family had absolutely no vision………….again. See, they have been thru this type of fiasco with me before.
Niko, my son, and I spent a day taking the bike apart. He had a blast as I just turned him loose with the tool chest, rags, and WD-40. I didn’t have to wash the bike off after he was done as most of the oil and grease was on him. GOOD, that’s what this project is about. He hasn’t had the chance like I did to bust his knuckles, bleed and tear shit up. In my opinion, the only way to learn is honest work.
As Clint the Squint once said, “A Man has to Know His Limitations.” I know mine, so no way was I going to tear into the Sporty motor and especially the tranny. Lucky me there is a guy in Albuquerque, NM who loves working on Ironheads. Chuck Zettner used to drag race with these motors so logically I took the motor/tranny down to him for the rebuild. Plan on a solid engine rework with a little extra “pop” and a rock solid rebuild of the tranny 4-speed, leaving it a kicker.
Remember earlier I mumbled something about a budget. Well that shit got thrown out the window with my first order. The nice folks over at Paughco helped relieve me of a real chunk of change. I’m sure glad it’s good quality stuff. That helps me justify the purchase. In fact the “quality thing” pretty much started my long slide into credit card oblivion.
Wow, lots of good quality stuff out there. I just had to have for this “ BUDGET” bike. Well at least I will teach my kids something, right! Then I got my 1st credit card statement. Holy Shit, they don’t need to learn that bad. Seriously folks, this stuff is out of site. I’m going back to Hot Rods and Sports Cars.
Serious sticker shock. No wonder everyone and their dogs are jumping into this game. Well maybe increased competition will bring some sanity back to the pricing table.
Anyway I’ll shut up and get back to the build. Henry at Paughco was a big help and got me squared away with a rigid frame, narrow springer, fuel tank, and an oil tank. He also talked me into an Exile sprocket rotor on the rear and a PM caliper and rotor on the front. Slade at Durango Harley-Davidson helped me out with the American radial wire wheels and Avon tires.
All the other parts were ordered from J&P Cycles, Dennis Kirk or Arlen Ness. All three companies have been great to work with. I have tried to look for some used stuff but it is hard to come by out here in fly-over country Durango, Colorado. When it came time to order the rear fender blank Bandit’s BikerNet had an ad for Todds Cycle. Todd was great to work with and suffered thru all my stupid questions with patience.
Now for the assembly mock up. First we installed the front end bearing cups. We didn’t have the neat cool cup installing tool but we did have a farm gate hinge that with the right washers worked great.
Next we installed the Paughco narrow springer front end, wheel and front brake.
After the front end was on we installed the Rear wheel and Exile sprocket rotor assembly. Temporary wheel spacers were installed for the mock up and most likely will need to be changed after the motor/tranny has been installed. (I am never that lucky.)
The fuel tank mounting hole was drilled and a tubing spacer was built to be welded in at a later date. I have to take the bike to my Dad’s shop to borrow his wire feed welding machine for all the welding.
After the tank we installed the dog bone risers, handlebars, Dakota Digital electronic tach, speedo, etc, Ness hand controls, Daniel Boone foot controls, spring seat, oil tank and oil coolers.
Well that’s it for now. We will check back in after the Powerplant for this thing is back. Should be sometime after Christmas.
