Dreamweaver build-off: HD Fatboy

pranava999 · 3rd August 2009, 13:20

I am sure that once it's ready, the urge to hit the road and feel the wind in your face will be overwhelming!

somspaple · 3rd August 2009, 13:32

Quote:

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.

and i wish that you'll get it registered and 'll be seen riding all over bangalore soon once the project is completed. come on we are tired of seeing sports bikes zipping around on the streets : bring out the custom HD. and of-course all the very best.

'72 Bullet · 3rd August 2009, 13:41

Wow, I really admire you to even think of doing something all on your own. It definitely is possible, it's just that most people won't try taking on such a large and complicated project. I have no doubt though this bike will be wonderful. Congrats!!

Just a few questions:
1) How does the suspension system work? The fat boy wasn't a hard-tail (though it looks like one) was it? Please explain. Also do tell us a little about what suspension you plan on using in the front as well as rear.

2) What did you fabricate the frame out of? Seamless MS pipe or an alloy of some kind?

3) A few details on the engine please. Where and how did you procure it? What did it cost and what was it originally meant for? I am not really a Harley enthusiast, so I am a little ignorant on the subject.

Thanks and all the best.

luky_13 · 3rd August 2009, 14:10

Quote:

Originally Posted by '72 Bullet

Just a few questions:
1) How does the suspension system work? The fat boy wasn't a hard-tail (though it looks like one) was it? Please explain. Also do tell us a little about what suspension you plan on using in the front as well as rear.

2) What did you fabricate the frame out of? Seamless MS pipe or an alloy of some kind?

3) A few details on the engine please. Where and how did you procure it? What did it cost and what was it originally meant for? I am not really a Harley enthusiast, so I am a little ignorant on the subject.

Thanks and all the best.

1. The fatboy rear is a softail suspension, the swingarm is attached to the frame using two shock absorbers. The front is hydraulic suspension.

2. The frame is made out of DOM tubing (drawn over mandrel, seamless)

3. The engine procurement is a long story which was procured for some other work, i will not divulge the detail on the forum. In nutshell its available for use on the project now.

luky_13 · 3rd August 2009, 22:20

Pics of some parts: Transmission, Motor, Frontend, Handlebar/Triple trees. Excuse the poor quality of images.

luky_13 · 5th August 2009, 18:41

Took apart the jig today to install the levelers. Machined flats to fit on the bottom of the square tubing, Hex head M10 bolts to go on the centre, will be used to adjust the level and will weld onto a circular flat which would be in contact with the floor.

Sankar · 5th August 2009, 19:14

Luky_13 good to read about your ongoing project. I wanted to something like this since long. Wonderful job mate. Just one doubt; How are you going to get it registered?

srijit · 5th August 2009, 20:46

Dont think he is going to bother getting it registered, from his post in the previous page.

Mpower · 5th August 2009, 21:14

Nice! what else are you fabbing other than the frame? Looks like you got an original front end too.

luky_13 · 5th August 2009, 22:08

As of now only the frame and the swing arm, the frame design is that of a 2005 harley fatboy, the engine is of a touring edition, the transmission is a 2001 manual 5 speed. The biggest challenge is to get these things to work together, because we are doing the frame in house it is one big variable.

Once its done we will spend a lot of time doing mock trials for alignment and component mating, before we go for the final assembly and frame powder coating. The other major challenge is the electricals.

Plan to go step by step, carefully.

howler · 10th August 2009, 14:38

whats the update on your progress?

Jonny Bravo · 10th August 2009, 15:22

Dreams finally taking shape

Congs Mate keep-up you efforts !

luky_13 · 10th August 2009, 20:52

Able to finish most of the parts required for the frame welding today. Small list
1. Stanchions - back from jig boring
2. Gussets - laser cut and ready to use
3. Neck - cnc machined and ground to K6 bearing tolerance
4. Frame tubing - downtubes, seat post, backbone etc all shot blasted and ready
5. Seat post mating clamp - ready
6. Backbone mating clamp - ready

Did a mock up on the jig today, tomorrow's plan is to finish all the coupe cuts and fish mounting checks on the tubing.

This is turning out to be more challenging than i thought, but i sleep with immense amount of satisfaction every night.

Rehaan · 10th August 2009, 22:24

luky_13,

Interesting project! And you seem to be doing it with a very close eye on quality / precision.

Can you tell us what the major differences between the original frame and your frame are likely to be? For one it will probably be slightly heavier right?

Keep the pics coming!
cya
R

bharti22shresth · 10th August 2009, 22:53

Amazing project! Eagerly looking at it. And once it's done, the century old question. "bhai, Mileage kya hai?"

3rd August 2009, 13:20	#16
pranava999 BHPian Join Date: Aug 2006 Location: BANGALORE Posts: 845 Thanked: 23 Times View My Garage	I am sure that once it's ready, the urge to hit the road and feel the wind in your face will be overwhelming!
	() Thanks

3rd August 2009, 13:41	#18
'72 Bullet BHPian Join Date: Dec 2008 Location: Semi-nomadic Posts: 143 Thanked: 11 Times	Wow, I really admire you to even think of doing something all on your own. It definitely is possible, it's just that most people won't try taking on such a large and complicated project. I have no doubt though this bike will be wonderful. Congrats!! Just a few questions: 1) How does the suspension system work? The fat boy wasn't a hard-tail (though it looks like one) was it? Please explain. Also do tell us a little about what suspension you plan on using in the front as well as rear. 2) What did you fabricate the frame out of? Seamless MS pipe or an alloy of some kind? 3) A few details on the engine please. Where and how did you procure it? What did it cost and what was it originally meant for? I am not really a Harley enthusiast, so I am a little ignorant on the subject. Thanks and all the best.
	() Thanks

3rd August 2009, 22:20	#20
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Pics of some parts: Transmission, Motor, Frontend, Handlebar/Triple trees. Excuse the poor quality of images. Attached Thumbnails
	() Thanks

5th August 2009, 18:41	#21
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Day 18: Jig Leveler Took apart the jig today to install the levelers. Machined flats to fit on the bottom of the square tubing, Hex head M10 bolts to go on the centre, will be used to adjust the level and will weld onto a circular flat which would be in contact with the floor. Attached Thumbnails
	() Thanks

5th August 2009, 19:14	#22
Sankar Senior - BHPian Join Date: May 2005 Location: Location Posts: 5,766 Thanked: 9,084 Times	Luky_13 good to read about your ongoing project. I wanted to something like this since long. Wonderful job mate. Just one doubt; How are you going to get it registered?
	() Thanks

5th August 2009, 20:46	#23
srijit BHPian Join Date: Jan 2008 Location: Trivandrum Posts: 598 Thanked: 8 Times	Dont think he is going to bother getting it registered, from his post in the previous page.
	() Thanks

5th August 2009, 21:14	#24
Mpower Senior - BHPian Join Date: Mar 2005 Location: Bangalore Posts: 10,409 Thanked: 1,730 Times View My Garage	Nice! what else are you fabbing other than the frame? Looks like you got an original front end too.
	() Thanks

5th August 2009, 22:08	#25
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	As of now only the frame and the swing arm, the frame design is that of a 2005 harley fatboy, the engine is of a touring edition, the transmission is a 2001 manual 5 speed. The biggest challenge is to get these things to work together, because we are doing the frame in house it is one big variable. Once its done we will spend a lot of time doing mock trials for alignment and component mating, before we go for the final assembly and frame powder coating. The other major challenge is the electricals. Plan to go step by step, carefully.
	() Thanks

10th August 2009, 14:38	#26
howler BHPian Join Date: Aug 2008 Location: coorg/bangalore Posts: 447 Thanked: 570 Times	whats the update on your progress?
	() Thanks

10th August 2009, 15:22	#27
Jonny Bravo BHPian Join Date: Nov 2008 Location: india Posts: 209 Thanked: 5 Times	Dreams finally taking shape Congs Mate keep-up you efforts !
	() Thanks

10th August 2009, 20:52	#28
luky_13 BHPian Join Date: Nov 2008 Location: Bangalore Posts: 580 Thanked: 156 Times View My Garage	Able to finish most of the parts required for the frame welding today. Small list 1. Stanchions - back from jig boring 2. Gussets - laser cut and ready to use 3. Neck - cnc machined and ground to K6 bearing tolerance 4. Frame tubing - downtubes, seat post, backbone etc all shot blasted and ready 5. Seat post mating clamp - ready 6. Backbone mating clamp - ready Did a mock up on the jig today, tomorrow's plan is to finish all the coupe cuts and fish mounting checks on the tubing. This is turning out to be more challenging than i thought, but i sleep with immense amount of satisfaction every night. Attached Thumbnails
	() Thanks

10th August 2009, 22:24	#29
Rehaan Team-BHP Support Join Date: Feb 2004 Location: Bombay Posts: 24,068 Thanked: 34,216 Times	luky_13, Interesting project! And you seem to be doing it with a very close eye on quality / precision. Can you tell us what the major differences between the original frame and your frame are likely to be? For one it will probably be slightly heavier right? Keep the pics coming! cya R
	() Thanks

10th August 2009, 22:53	#30
bharti22shresth BANNED Join Date: Nov 2008 Location: panchkula Posts: 362 Thanked: Once Infractions: 0/1 (10)	Awsome!!! Amazing project! Eagerly looking at it. And once it's done, the century old question. "bhai, Mileage kya hai?"
	() Thanks