[pranava999]

Whoaa...coming in after a long time!!I remember, the days when you started the thread and were working on the design, and now to see how far you have progressed, is just awesome.Congrats. It's a stunner!

[invincible7]

WOW... Congratulations man, she is a beast in a beautiful shell.

Kudos to your hardwork and passion, never seen anyone so focussed towards one bike.

[BIG SARAN]

What a beauty !!!! Heartiest Congratulations Sir. Was waiting for this post for sooo long. Can't wait it see it thundering on the roads.

All the best.

Ride Hard.

[m3_07]

Lucky 13 .....You Sir have done a wonderful job. I have come across very few people who have had that span of patience you have exhibited. It is really an honour to have a fellow Banglorean/ Indian to have accomplished this feat.

PS: OT, it would be really interesting to know what HD feels about this project, with all their R&D one one side & Your most competent/ ACCOMPLISHED team on the other??

Once again....Congratulations Sir !!

[Rennjit]

luky_13. Building up a frame from scratch that too for a heavy machine, just awesome! we wait for build pics & story..

[luky_13]

Picking up the story where I last left it - Wiring harness. I quickly realized how intimidating this was and actually making me nervous. Routing the wiring harness was proving to be a challenge, had to make sure none of the wires got pinched while riding. We must have installed and uninstalled the harness around half a dozen times. Some Deutsch connectors had to be crimped, complete headlamp wiring had to be figured out. I actually managed to connect the headlamp to the horn switch, can you beat that! With a lot of help from the Softail Electrical Diagnostic Manual we ultimately got the job done to satisfaction.

[luky_13]

Fixing the carb was quite simple, pushed it into the intake manifold and wired throttle and idler cables. Then connected the fuel pipe and choke cable. We used good quality silicone tubing (locally available) for fuel delivery.

[ramki067]

luky_13,
If HD comes to know about this project by you, they might hire you with a fat compensation!!! Great job there...Kudos to your hard work sir.

Rgrds.

[dustom_99]

Wow such neat work.that truly is a job well done.
I guess you are going to beat HD at there own game of build quality.
If you go ahead for the process of registering your bike,plz let me know about it.thanks in advance.
If few more people crop up like you,who would wana build there own ride,India is going to be 'The new USA' as far as bike building goes.

[luky_13]

I had thought that fixing the primary drive would be breeze. We started with the primary chain case, installation was pretty simple and neat. Next on, the compensator sprocket and the clutch hub (basket) required a chain locking tool... so we quickly handcrafted one., very rudimentary but does the job.


More pics, compensator installed and torqued


Clutch hub, installed.


Adjuster nut, tension adjusted and torqued


An alignment issue cropped up, taper of > 10mm between the clutch and compensator


Anyway we used a hardened-ground spacer to rectify it and then finally

[download2live]

Oh My God.
This is awesome.
Seeing activity on this thread after a long time.
Wish to see this on roads. Fast.
You must have spent quite a bit on this I guess.

[Ravindra M]

Originally Posted by luky_13

I have stopped accounting the expenses . Will never think about RTO registration etc, for me the very thought of having a harley parked in my driveway build by me from scratch is overwhelming. I don't mind if its not road worthy or registered.

@luky_13 : Mindboggling is what comes to mind when I read through. Great work in progress I must say !!

Have you another thought about RTO registration yet ?

[luky_13]

Even though we did mock-up the exhaust before sending the frame for powder coating, the exhaust brackets and final install was a bit of a mystery. The unbalanced engine added to some level of Fear-Factor as the exhaust setup I had was meant for the balanced version of TwinCam (lesser vibrations). Uncertainty ruled, didn't know what to expect out of 'this' marriage. But before that we had to get the exhaust mounting bracket dialed in parallel to the floor to finalize the mounting points.

Is it parallel, yes it is...


Drill a hole, 8mm in this case


Tap, M8


Install the allen screws to check again


Verified and installed SS allen screws with a little help from our friend from Loctite

[luky_13]

Laid out the complete setup on a work table for easier assembly. Started with the two small brackets that hold the mufflers together


Installed the interconnect gasket and seal




Installed the 2 clamps and 1 mounting bracket


Finally goes where it belongs

[luky_13]

Always thought that the kick stand was no big deal and that we should be able to retrofit a similar sub-assy from an Avenger. As we were approaching completion of the bike the kick stand was becoming a necessity, couldn't get her off the stand without it. So we got one from Bajaj and tried to retrofit, quickly realized that neither it could take the weight of this 700 lb behemoth nor was the banking angle optimal. I had always wanted to use some parts on the bike which held a lot of sentimental value for me, one of them was my old golf putter. I used it for many years when I was young and incidentally my father dropped it over at my place last time he visited.


With the putter in front of me I was getting a lot of ideas for the kick stand. Soon enough I decided that the putter head would form the bottom end of the stand and work started in a jiffy, dismembered the shaft from the head.

DIY : Shaft removal from putter - YouTube