Dreamweaver build-off: HD Fatboy

luky_13 · 15th December 2011, 12:45

After all the good news, some bad ones...

After firing it half a dozen times the starter motor was spinning but not engaging the primary drive at all
The battery wasn't charging, niether at idle not at higher rpm's
Oil leak from 3 places
While running the bike was misfiring badly (through the exhaust)
Realized that the oil tank was too close to the starter motor +ve connection screw. Dangerous!
Depressing the Clutch lever was a herculean task (too hard)

More after some in-depth analysis.

Ajaybiz · 15th December 2011, 13:14

Starter motors solenoid switch must be not working.
Battery not charging means either rectifier is not working or loose connection, check the voltage at charging terminals.
Oil leak is OK not a big issue happens with most of the builds, I use araldite with packing kit to make it 100% leak proof.
Misfiring or detonating continuously?, happens with high compression bikes with Indian low octane fuels, else your ignition timing is out, don't ride the bike till you sort out this issue, detonation can make a hole in pistons.
Clutch is cable operated or Hydraulic ones, my bad as never had Harley so just asking as with Hydraulic system it should work as it should be.

luky_13 · 15th December 2011, 21:25

@Ajaybiz, thanks for the tips.

The original starter had gone kaput (was a used one off eBay). Solenoid was fine motor was spinning, but the bearings gave up. One tooth on the internal gear had broken, that did all the damage.

Solution: I had a spare starter in stock, and we were quick to get our hands dirty again. It actually created a lot of mess as we had to drain out the engine oil, but the oil lines kept dripping ... slowly

Dismantled again

A new sparkling starter goes in
Took this opportunity to adjust the sagging oil tank and get its coordinates right this time.
Fixed all the oil leaks, they were minor and probably because I did not torque the drain plugs to spec.
Fine tuned the clutch, much better now
Battery wasn't charging as the pins of the deutsch connector from alternator to voltage regulator had not seated properly. Removed and fixed properly and wallah the battery started to charge.
Tuned the carb, it was probably running a bit to lean. Misfiring disappered.

All problems sorted out and I'm a happy man. Will fight with the front and rear disc brake calipers tomorrow.

luky_13 · 27th December 2011, 19:47

With most niggling issues at bay it was time for the Fatboy to get its final piece of jewellery: the Primary drive cover. Other small parts were installed: Shifter, Foot pegs and a few more. A bit of adjustment on the clutch adjuster screw and...

Dreamweaver build-off: HD Fatboy-dsc_0133.jpg

... Merry christmas!

Dreamweaver build-off: HD Fatboy-dsc_0146.jpg

Dreamweaver build-off: HD Fatboy-dsc_0152.jpg

luky_13 · 27th December 2011, 20:04

The last piece of the puzzle: Brakes. Couldn't rely on the old brake pads, these calipers were bought around 4 years back. Time to change them ( i guess the process remains the same on most disc calipers)

Loosen the torx screw

Dreamweaver build-off: HD Fatboy-dsc_0447.jpg

Position a flat screw driver between the pads to relax the caliper pistons while loosening up

Dreamweaver build-off: HD Fatboy-dsc_0448.jpg

Opened

Dreamweaver build-off: HD Fatboy-dsc_0449.jpg

The Treatment

Dreamweaver build-off: HD Fatboy-dsc_0451.jpg

Done and immediately afterwards bled the brakes with some fresh DOT4 brake fluid.

Dreamweaver build-off: HD Fatboy-dsc_0453.jpg

luky_13 · 28th December 2011, 21:40

Some say a Harley is never complete, I can say that my build has reached a landmark. Although far from over, now when I reflect back I realize this build has taught me a lot of things. It taught me how to focus and say 'No' to umpteen other distractions, it taught me to be patient, it taught me not to believe someone who said 'this can't be done', it taught me how to harbor positive spirits. It has been amazing to share, receive feedback, appreciation and applause. Thank you.

Well coming back to her: She runs just fine, looks beautiful and as of now the speedo just reads 65 Km. Some things that I intend doing over time:

1. Dual carb setup
2. Oil cooler
3. Chrome custom cut wheels
4. LED lamps
5. King-Kong-Klutch
6. 6 speed baker tranny
7. 240 rear wheel
8. Vance & Hines duals
9. Custom foot pegs
10.Performance machine brake calipers
11.Floating disc's

... the list just goes on and on and is constantly variable, meanwhile one more shot.

Dreamweaver build-off: HD Fatboy-dsc_0234.jpg

shrini78 · 28th December 2011, 21:46

Check Motherwell solo rack so you can fabricate it,you wont scratch or knick your rear fender.

Ajaybiz · 29th December 2011, 10:29

Just one word, Beautiful.
Not sure about other changes but keep dual carb and oil cooler first in your list.

luky_13 · 29th December 2011, 11:32

Quote:

Originally Posted by shrini78

Check Motherwell solo rack so you can fabricate it,you wont scratch or knick your rear fender.

Shrini, we are in the process of fabricating a rear seat owing to pressure from 'home'. That should take care of the rear fender.

bivin · 30th December 2011, 03:13

great work!!! good to see that your work of months has finally paid off!! she looks hot!!! please post some on road pics as well!!

Leepower · 30th December 2011, 15:15

Quote:

Originally Posted by luky_13

Shrini, we are in the process of fabricating a rear seat owing to pressure from 'home'. That should take care of the rear fender.

Amazing work man. I have a query. Are you planning to get her registered and if yes then how??? If no then where are you gonna ride her???

akshayasok · 4th January 2012, 05:32

thats absolutely inspiring, well done mate.

quakerme · 5th January 2012, 14:19

Quote:

Originally Posted by luky_13

Some say a Harley is never complete, I can say that my build has reached a landmark. Although far from over, now when I reflect back I realize this build has taught me a lot of things. It taught me how to focus and say 'No' to umpteen other distractions, it taught me to be patient, it taught me not to believe someone who said 'this can't be done', it taught me how to harbor positive spirits. It has been amazing to share, receive feedback, appreciation and applause. Thank you.

Well said, it was an inspiring thread. Loved reading every single post wishing you all the best. Waiting for more road pics and reviews, would be awesome to see this beauty on road.
So it is a 2012 custom made HD softail ..Happy new year mate!

Dr.Awesomeness · 5th January 2012, 14:53

Hats off to your perseverance, you have some how made me even more proud to be an Indian, by making an American piece of engineering marvel fro scratch in india. If only we have more of you guys who have more "patience than a Buddhist monk" running our country, waiting for your road tests.

, Bravo my friend Bravo.

contactme27 · 5th January 2012, 16:35

Seriously, a great hard work and it paid off. The design outcome is wonderful. Eager to see the on road experience.

15th December 2011, 12:45	#271
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Re: Dreamweaver build-off: HD Fatboy After all the good news, some bad ones... After firing it half a dozen times the starter motor was spinning but not engaging the primary drive at all The battery wasn't charging, niether at idle not at higher rpm's Oil leak from 3 places While running the bike was misfiring badly (through the exhaust) Realized that the oil tank was too close to the starter motor +ve connection screw. Dangerous! Depressing the Clutch lever was a herculean task (too hard) More after some in-depth analysis.
	() Thanks

15th December 2011, 13:14	#272
Ajaybiz BANNED Join Date: Nov 2004 Location: Bangalore Posts: 1,440 Thanked: 320 Times View My Garage	Re: Dreamweaver build-off: HD Fatboy Starter motors solenoid switch must be not working. Battery not charging means either rectifier is not working or loose connection, check the voltage at charging terminals. Oil leak is OK not a big issue happens with most of the builds, I use araldite with packing kit to make it 100% leak proof. Misfiring or detonating continuously?, happens with high compression bikes with Indian low octane fuels, else your ignition timing is out, don't ride the bike till you sort out this issue, detonation can make a hole in pistons. Clutch is cable operated or Hydraulic ones, my bad as never had Harley so just asking as with Hydraulic system it should work as it should be.
	(1) Thanks

15th December 2011, 21:25	#273
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Re: Dreamweaver build-off: HD Fatboy @Ajaybiz, thanks for the tips. The original starter had gone kaput (was a used one off eBay). Solenoid was fine motor was spinning, but the bearings gave up. One tooth on the internal gear had broken, that did all the damage. Solution: I had a spare starter in stock, and we were quick to get our hands dirty again. It actually created a lot of mess as we had to drain out the engine oil, but the oil lines kept dripping ... slowly Dismantled again A new sparkling starter goes in Took this opportunity to adjust the sagging oil tank and get its coordinates right this time. Fixed all the oil leaks, they were minor and probably because I did not torque the drain plugs to spec. Fine tuned the clutch, much better now Battery wasn't charging as the pins of the deutsch connector from alternator to voltage regulator had not seated properly. Removed and fixed properly and wallah the battery started to charge. Tuned the carb, it was probably running a bit to lean. Misfiring disappered. All problems sorted out and I'm a happy man. Will fight with the front and rear disc brake calipers tomorrow.
	(2) Thanks

27th December 2011, 19:47	#274
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Re: Dreamweaver build-off: HD Fatboy With most niggling issues at bay it was time for the Fatboy to get its final piece of jewellery: the Primary drive cover. Other small parts were installed: Shifter, Foot pegs and a few more. A bit of adjustment on the clutch adjuster screw and... ... Merry christmas!
	(2) Thanks

27th December 2011, 20:04	#275
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Brakes The last piece of the puzzle: Brakes. Couldn't rely on the old brake pads, these calipers were bought around 4 years back. Time to change them ( i guess the process remains the same on most disc calipers) Loosen the torx screw Position a flat screw driver between the pads to relax the caliper pistons while loosening up Opened The Treatment Done and immediately afterwards bled the brakes with some fresh DOT4 brake fluid.
	(1) Thanks

28th December 2011, 21:40	#276
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	A journey has started! Some say a Harley is never complete, I can say that my build has reached a landmark. Although far from over, now when I reflect back I realize this build has taught me a lot of things. It taught me how to focus and say 'No' to umpteen other distractions, it taught me to be patient, it taught me not to believe someone who said 'this can't be done', it taught me how to harbor positive spirits. It has been amazing to share, receive feedback, appreciation and applause. Thank you. Well coming back to her: She runs just fine, looks beautiful and as of now the speedo just reads 65 Km. Some things that I intend doing over time: 1. Dual carb setup 2. Oil cooler 3. Chrome custom cut wheels 4. LED lamps 5. King-Kong-Klutch 6. 6 speed baker tranny 7. 240 rear wheel 8. Vance & Hines duals 9. Custom foot pegs 10.Performance machine brake calipers 11.Floating disc's ... the list just goes on and on and is constantly variable, meanwhile one more shot.
	(16) Thanks

28th December 2011, 21:46	#277
shrini78 BHPian Join Date: May 2009 Location: Houston, TX Posts: 258 Thanked: 56 Times	Re: Dreamweaver build-off: HD Fatboy Check Motherwell solo rack so you can fabricate it,you wont scratch or knick your rear fender.
	() Thanks

29th December 2011, 10:29	#278
Ajaybiz BANNED Join Date: Nov 2004 Location: Bangalore Posts: 1,440 Thanked: 320 Times View My Garage	Re: Dreamweaver build-off: HD Fatboy Just one word, Beautiful. Not sure about other changes but keep dual carb and oil cooler first in your list.
	() Thanks

30th December 2011, 03:13	#280
bivin BHPian Join Date: Aug 2009 Location: India Posts: 982 Thanked: 230 Times	Re: Dreamweaver build-off: HD Fatboy great work!!! good to see that your work of months has finally paid off!! she looks hot!!! please post some on road pics as well!!
	() Thanks

4th January 2012, 05:32	#282
akshayasok BHPian Join Date: Jan 2010 Location: MCR,GVA,TVM,BGR Posts: 44 Thanked: 10 Times	Re: Dreamweaver build-off: HD Fatboy thats absolutely inspiring, well done mate.
	() Thanks

5th January 2012, 14:53	#284
Dr.Awesomeness BHPian Join Date: Jul 2011 Location: Bangalore Posts: 131 Thanked: 169 Times	Re: Dreamweaver build-off: HD Fatboy Hats off to your perseverance, you have some how made me even more proud to be an Indian, by making an American piece of engineering marvel fro scratch in india. If only we have more of you guys who have more "patience than a Buddhist monk" running our country, waiting for your road tests. , Bravo my friend Bravo.
	() Thanks

5th January 2012, 16:35	#285
contactme27 BHPian Join Date: May 2004 Location: Hyderabad Posts: 225 Thanked: 21 Times	Re: Dreamweaver build-off: HD Fatboy Seriously, a great hard work and it paid off. The design outcome is wonderful. Eager to see the on road experience.
	() Thanks