JTH's HD 883 Dual Sport'ster conversion

[Slvrtundevl]

Simply AWESOME!

[jub jub]

Originally Posted by Slvrtundevl

Simply AWESOME!

My thoughts exactly. Very nice build!

[JimmyTheHog]

Heres our new Fly Screen Wind Deflector for the SC3 Adventure. Its made from 5052-H32 Aluminum and Polycarbonate. Its weighs about a pound and is designed to protect the gauges from branch or flying debris damage and deflect wind from the body. The seam gap shown at the bends will be welded and ground smooth.

Its being fabricated now. Hope to have it on the bike in a few weeks.

[DRjoe]

This is all far too impressive.
Can't you bodge something up with some silicone and race tape just to make us feel better about ourselves.

[dpetersak]

Hey Jim,

I know you're at 18mm of offset, but I'm wondering if you've tried 22mm, or if the difference between 18 and 20 was significant. I need to get the triple clamps away from the rubber-mount frame as much as possible to maximize my turning radius and avoid any frame alterations. This will reduce my trail, but I'm hoping that with a 30 degree rake the effect will be minimal. More responsive, yes, but not unstable. Thanks for your help.

Cheers,

Dave

[JimmyTheHog]

Originally Posted by dpetersak

Hey Jim,

I know you're at 18mm of offset, but I'm wondering if you've tried 22mm, or if the difference between 18 and 20 was significant. I need to get the triple clamps away from the rubber-mount frame as much as possible to maximize my turning radius and avoid any frame alterations. This will reduce my trail, but I'm hoping that with a 30 degree rake the effect will be minimal. More responsive, yes, but not unstable. Thanks for your help.

Cheers,

Dave

Hey Dave - Ive just had the 18mm offset triples on the bike, so I cant say for sure. I know when I was playing with the rear shock height & fork height (up or down in the triple clamps), it did have a pretty significant effect on the stability of the bike, but only at around 60-70'ish mph. The steeper the rake and the taller the bike, the less stable it was and would get some wobbles. At the lower speeds, not a problem.

My rough geometry layouts show the following trails at 30deg rake:
18mm = 5.57" trail
20mm = 5.50" trail
22mm = 5.43" trail

All still pretty generous trails, but we cant neglect the rake change too. As the offset increases, the rake decreases. Its subtle, but subtle changes in geometry at high speeds can be enough to shift the resonances.

So, you may just have to go there and see how it does. Kind of like an aircraft test pilot - get going at speed and see what happens.

For turning radius, I wanted to improve mine too, so my new triple clamps moved the bolt clamps to the front so I would get more clearance on the bottom clamp to the frame. It maybe bought me a 1/4" or more which doesn't seem like much, but in radians it should help a bunch. I also integrated a Scotts steering stabilizer. Even know the bike is stable at speed, bumps can upset it and get some wobble. So, if you find the 20-22mm is unstable, you can always try a stabilizer.

Hope this helps.

[JimmyTheHog]

Originally Posted by DRjoe

This is all far too impressive.
Can't you bodge something up with some silicone and race tape just to make us feel better about ourselves.

Ha ha! - you should see the old truck I drive I put all my efforts in my passion, and the rest of my stuff is held together with zip ties, wire and duct tape. I guess its just priorities.

[dpetersak]

Thanks, Jim. You're the man!

[Bambi]

Hello out there,
concerning this:
'
Quote:

Originally Posted by DRjoe This is all far too impressive. Can't you bodge something up with some silicone and race tape just to make us feel better about ourselves.

Ha ha! - you should see the old truck I drive I put all my efforts in my passion, and the rest of my stuff is held together with zip ties, wire and duct tape. I guess its just priorities.
__________________
Jim'

Applause to both of you, you made my day!!!
Kind regards, Bambi

[JimmyTheHog]

The designs usually don't start off looking polished in CAD. Its a progression. The design process for me starts off with an abstract vision of what I want. Then I try different things until it looks and works right. For the fly screen, it took a cardboard mockup, then a paper scaled model to hold and see how it looked, and then the full finished 3D model on the bike assembly.

Heres a pic of the progression... Also, the aluminum tube behind the cardboard is the mockup for the crashbars.

[WhicheverAnyWayCan]

Hi,

In case you have forgotten about the rubber mount for fuel tank of 86-03- My friends and I was taking engine off my sportster yesterday so I could do some engine works to it soon. In the process, I found that you could remove the rubber mount so it is possible that you could just make a special bracket for the 86-03 while making your fuel tank universal to 04+??

Just thought I would offer my input.. here is a pic of rubber bracket removed (bolt) and I am holding the piece under the frame straight down from the hole it would go in:

[JimmyTheHog]

Originally Posted by WhicheverAnyWayCan

Hi,

In case you have forgotten about the rubber mount for fuel tank of 86-03- My friends and I was taking engine off my sportster yesterday so I could do some engine works to it soon. In the process, I found that you could remove the rubber mount so it is possible that you could just make a special bracket for the 86-03 while making your fuel tank universal to 04+??

Just thought I would offer my input.. here is a pic of rubber bracket removed (bolt) and I am holding the piece under the frame straight down from the hole it would go in:

Thanks for the input - very much appreciated. The new gas tank mounts like the Storz aluminum tank with a bolt attached to the backbone (either with a welded bracket or a hose clamped one like some Clarke tanks use) and also supported in the front from where the ignition coils hang - which looks like a similar hole, but towards the front.

If I could ask - could you take another picture of the front of the backbone near the steering stem to see if that same basic mounting hole is there? Thanks in advance!

[WhicheverAnyWayCan]

Originally Posted by JimmyTheHog

If I could ask - could you take another picture of the front of the backbone near the steering stem to see if that same basic mounting hole is there? Thanks in advance!

Sure, I think this is what you wanted? I hope this angle is good for you?

The first hole on left is what you use to hold the fuel tank bolt and 3rd hole from left to right is for ignite module bracket bolts.

[WhicheverAnyWayCan]

One quick question about volt regulator.. is your still in the original location? I have thought about possible of relocating it but am concerned about getting enough air flow to go through it to keep it cool, and the way the wire harness is designed, it looks like maybe relocating is not possible? Any thought?

[JimmyTheHog]

Originally Posted by WhicheverAnyWayCan

One quick question about volt regulator.. is your still in the original location? I have thought about possible of relocating it but am concerned about getting enough air flow to go through it to keep it cool, and the way the wire harness is designed, it looks like maybe relocating is not possible? Any thought?

Thanks for the pictures. Looks promising.

Yes, I kept the volt regulator in the same place for now. Same concern - you want to keep it well cooled. Not sure how well it will do over time there though if it gets hit by rocks or debris from coming off the front tire. Also, if you do any mud riding and it gets coated - it could be a problem. Its up fairly high, so hopefully its ok there - we shall see. If it becomes a problem, then I'd consider moving it. I did remove my horn though, which was mounted right above it. This opened up more air flow to the motor.