JTH's HD 883 Dual Sport'ster conversion

[JimmyTheHog]

D4u2 - I know what you mean about trail riding. Ive ridden trails for a long time, but ive never tried a steering stabilzer. I may have to give one a try and see.

Scotts has decided to send me a dead body (so to speak) of their steering stabilzer so i can make the mounting provision accurately. Great customer service from Scotts - thanks Jake!

[JimmyTheHog]

SC3 Triple Clamps: The new triple clamps design is done and now has the Scotts steering stabilizer integrated. It fits between the bar risers and under the handlebars. This keeps the stabilizer tower pin nice and short to minimize deflection.

Next step - cut metal....

[WhicheverAnyWayCan]

Originally Posted by JimmyTheHog

Yes, i do plan to market these. Im hoping to get close to 6 gallons as the solid model is slightly over that so with wall thickness and when mold shrinks a bit, it should be close.

As for the 05 model - this tank is designed to fit the 93-03 Sportster models. I havent checked the 04-06 rubber mount models yet, but im hoping it will fit them. Theyre still carb'ed those years, so no issue with FI pumps like in the 07's and later. When i find out, i will post an update.

If I am not mistaken, I think that the piece that hold fuel tank for pre-04 is located differently from the 04-06 and 07+? I tried to see if I could put a 04+ 4.5 gallons of fuel tank on my 98 and it would not fit due to different fitment. But you could always try to design the tank to work with both pre-04 and 04-06 (non-carb years) before producing them?

And don't forget that I am also in market for your 6-gal tank

[JimmyTheHog]

That is the plan - I just need to get my hands on an 04-06 and check out the fit with my foam mock-up tank.

This tank doesnt use the stock mount at the rear. It uses the frame backbone with rubber pads to support the weight of the tank w/ gas and to attach a bolt (clamped or welded bracket like the Storz tank) that goes thru the top center of the tank. It also has brackets on the front of the tank that mount to the 93-03 tank mounting points. These are to support any front-to-rear movement or inward deflections. Since the brackets bolt on, if the 04-06 have different mounting locations, then I can make different brackets if theyre generally in the same location.

Anyone else out there with an 04-06 Sportster that has any info on tank mounting differences? Some pictures would be good to see.

This picture shows the mounting brackets and center hole...

[JimmyTheHog]

Heres a B&W monochrome pic my wife took - it was a good lighting day for pictures.

I also just added the vent slots in the front fender for better air flow to the motor.

[kellymac530]

Jimmy,
That is a great pic. Your bike is custom dual sport art. Just plain trick and cool.

If you get time, can we get some shots of your fender slots?

Did you cut slots and then heat and bend them open or what? They look like they protrude back from the fender.

Keep it up sir.

[DC,Chad]

Originally Posted by JimmyTheHog

Heres a B&W monochrome pic my wife took - it was a good lighting day for pictures.

I also just added the vent slots in the front fender for better air flow to the motor.

stunning beauty of a bike

[JimmyTheHog]

Theres nothing fancy with the slots - I just had some 3/8" slots milled in. Here's a pic of them. Im going to do some temp measurements with the slots and then tape them up and compare to see the improvement.

There is an aftermarket fender that has pre-formed slots posted somewhere in this thread though.

[kellymac530]

Thanks Jimmy.

PS: There are WAY too many tits on that front tire....you need to get out and ride.

[JimmyTheHog]

Originally Posted by kellymac530

Thanks Jimmy.

PS: There are WAY too many tits on that front tire....you need to get out and ride.

Haha! - Youre right on that!!! I just put these tires on not too long ago (2nd set), then it got cold and rainy - im a cold weather wimp. I know, im in sunny CA, stop complaining and get out and ride

[kellymac530]

I am in Sunny Southern California and it has been crazy cold here for weeks. It has been awesome the last 4 days or so...go riding.



I have been able to get off the couch this last week a bit so I officially started my RT to GS"B" project...1/2 hr incriments until I am cleared by my ortho surgeon...but tinkering is giving me something to do.

[dpetersak]

It's like a work of art, Jim, that keeps getting better. I'm working on putting an Acerbis fender on mine, also slotted.

[JimmyTheHog]

That's looking good! But your rear spring rate may be a bit too stiff

[JimmyTheHog]

Some fun with CAD while waiting for new front end parts to be completed. This is the new 6 gal gas tank rendered in Autodesk Showcase.

[IMG][/IMG]

[DC,Chad]

Nice VERY Nice