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Old 12-11-2012, 10:55 AM   #526
kellymac530
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Glad I did not offend with my thoughts. Good idea keeping it service able at HD dealers for long distance travel purposses.
I was purely thinking of weight.

I agree on the shocks being a cool old school style and if they work good then all is good. I was purely curious as to the change reason, makes good sense especially since you thinking or even trying to market this as a kit, or at least parts of a kit. The good old KISS mentality. (Not that YOU are stupid....refereing to my self there)

Great stuff here Jimmy, thanks for the detailed thread. That is a really good weight for a big twin ADV bike. I think I want one...
At the very least, I want my buddy to build one so I can have him Beta test it.
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Old 12-11-2012, 11:07 AM   #527
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One more quick question if I may,
It looks like you are running a stock KTM 2 piston front brake caliper on an extension bracket and a 320mm rotor, is that correct?

How do you feel it works on a close to 500# bike?

I am prepping to start a bike build and collecting parts and I have some negative input on my plans that my brake ideas are in no way enough, but I think they will be fine. I have a respectable inmate who builds alot of bikes insisting that not running a dual disc set up off of a big KTM twin will not be enough but I see alot of guys running the setup you have and see no big complaints.

Are you a heavy front brake user or a more typical HD rider and tend to use more rear?

I have raced MX for 40+ years and am a BIG front braker, My motto is "front brakes stop a motorcycle, rear wheel steers a motorcycle"....over simplified of course, but useable advice.

Thanks again JTH.
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Old 12-11-2012, 07:47 PM   #528
JimmyTheHog OP
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KMac - Correct on the front brake. Its a KTM 2-pistion Brembo from a 525EXC, 320mm rotor, and extension bracket. Braided SST brake line and an Oberon adjustable brake lever on the stock Sportster master cylinder running DOT5.0 silicone. Im forgetting what brake pad material i have, but what ever stock KTM uses, thats it.

As far as braking power - for me, its adequate with this setup, but im a light braker. Having the adjustable lever made it better to get the max squeeze for my hand size. That being said, Ive had GS's, HP2's, 950SE, and 950/990 Adv's and all brake better than this setup. For offroad riding, i actually like it not being too grabby though. I crashed an HP2 in the dirt from a too grabby front brake once. For the on-road, i would actually like a bit more stopping power, but as i said - its adequate and have had to brake hard a few times and it gets the job done no problem. It does stop when the lever is pulled. Just takes a bit more pull force. The 320mm rotor was the big difference.

Im going to try a different pad material and that may be the ticket to a bit better on-road braking. I'll post when i do it.

If youre a hard front braker and like that - this setup will probably feel underbraked for you - unless the different pad material makes a difference.
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Old 12-11-2012, 09:46 PM   #529
Roadracer_Al
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Are you planning to have the tank shaped in steel?
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Old 12-11-2012, 10:31 PM   #530
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No on the steel. The primary plan is to make it plastic.
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Old 12-12-2012, 01:52 PM   #531
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Plastic like FRP, or plastic like rotomolded dirt bike tanks?

If the latter, I'd be interested to know costs and a source.

That kind of information is just good to have, you know, just in case.
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Old 12-12-2012, 07:36 PM   #532
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Rotomolded XLPE. Im working on selecting the right supplier now, so cant disclose anything yet.
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Old 12-13-2012, 09:23 PM   #533
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Thanx a ton for your reply Jimmy.
Very cool of you to take time to answer my question while you are still working on this great machine.
I am pounding out some details for a build myself and an inmate here has given me some great advice on brakes and getting to some other ideas is very helpful.
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Old 12-25-2012, 02:21 PM   #534
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Happy Holidays everyone!

New projects for 2013 are already in progress:
- 6 gal gas tank - Aluminum prototype to start, then plastic to follow
- Crash bars
- Triple Clamps
- ???



CRASH BARS: To go along with the larger gas tank, I'll be adding a crash bar to protect the tank and petcocks in case of a low side fall and also to mount some new LED flood lights.












TRIPLE CLAMPS: Triple Clamps design is close to done. These are stronger than the ones im using now and will allow for more turning radius as the clamps have been moved to the front and provide more clearance to the frame.



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Old 12-25-2012, 07:33 PM   #535
MitchG
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Keep up the good work Jim! You've got at least one victim in me...
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Old 12-25-2012, 08:00 PM   #536
DRjoe
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your pretty handy cad then
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Old 12-25-2012, 08:07 PM   #537
WhicheverAnyWayCan
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JimmyTheHog,

You don't have to buy your Triple Tree if buying your fuel tank? I was hoping to stay with my own Triple Tree while using your fuel tank.

Thanks!
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Old 12-25-2012, 08:22 PM   #538
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Quote:
Originally Posted by WhicheverAnyWayCan View Post
JimmyTheHog,

You don't have to buy your Triple Tree if buying your fuel tank? I was hoping to stay with my own Triple Tree while using your fuel tank.

Thanks!
No, you dont need to. The stock KTM 525 triple clamps or the Applied Racing (for KTM) triple clamps will work with the tank as is. For others clamps, i would need to check the dimensions, but the tank has generous clearance for the forks and clamps, so unless youre using something really wide, they should fit.

These new triple clamps will be stronger & stiffer for the increased weight of the Sportster and give a bit more turning radius now that the new tank allows for that. Ive also integrated the Sportster rubber handlebar dampers into the bar risers - keeps motor vibration to the hands down to a minimun.
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Old 12-26-2012, 10:38 AM   #539
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What forks will your triple tree accommodate?

(If that is a silly question, please excuse me. I've never changed changed or researched forks before, but plan to in this upcoming project.)
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Old 12-26-2012, 11:31 AM   #540
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Are you (or have you considered) putting steering damper mounts on the triple clamp? It should be a pretty easy addition, just a couple of threaded holes. It would work much better than a bracket that gets added on afterwards, especially if the bracket is attached to the handlebar side of the rubber mount.

I have no idea if your bike would be helped much by a steering damper, but lots of people like them on other bikes.
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