2014 winter mods to my bob

JRK5892

Over 1,000 Posts
Figured it was time to share what i have going on... i loved my old fairing but it was just a bit too big for me and would not allow me to really cut turns hard... so after i sold my touring setup i went back to the drawing board... the fairings i have found on the market are just too small. so i tracked down a 70's rifle sport fairing and fell inlove... yes it is ugly but i have not started on it.

My wife and I just had another child so i am not in the shop very late anymore so i brought my bike home to build in my home shop to allow me to be close and still get stuff done... here is the plans

Fairing: keep as LIGHT as possible, all quick release, 6"compontent stereo glassed in inner fairing, USB charging port, GPS dock, Iphone mount, radar detector, fiberglass stock turn signals in

Bags: FLH bags, move the mounts inside the bag to allow me to move the bags as close to the rails as possible. glass the inside for support, remove the stock mounts and use police style hinges and locks

brakes: braided lines, brembo front, shave and powder the rear and front calipers

Rotors: still not sure

Floorboards: Moving my floor boards back 2" and down 1" so custom mounts and shifter/brake will have to be fab'd up

shocks: possible air ride with bash guard and/or nose cone

here is where i stand so far.. being that i have a 17month old at home and now a 2 week old, things will go slow but i will updated as i go!

sample tags shot to send to painters all over the place to try and match... my money is on Dave from Davocustoms on here
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quick mock up
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possible idea for brake as i do have 300mm 11.8 rotors
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Thank you to Richard at HD Custom Fab for the custom derby cover
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already 3 toned it to match the bike
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stereo gear and some of the rings i will use to fiberglass the inner fairing:
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my home shop manager hard at work:
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saddle bag option #1
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option #2
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how they would stick out normally
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how they will ride when i am done
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removed all the hardware, rats nest, rust, gunk, etc off the fairing to prep for mods
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marked the areas to be filled in
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saved all the stock trim, and cleaned that up
Before:
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After: (back to black is awesome stuff)
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started the mounts for the fairing
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ok well got a bit more done... as i mentioned this is going to be slow going as i am working on this when i have some free time from the shop and the 2 little ones i have at home... finally was able to score a brembo caliper, sucks balls it is chrome, will make it a night mare to shave and suck a bit more for powder, but i got it decent priced for under $150.. with new braided lines this should be a nice little upgrade to the front brakes without having to do a ton of mods and spend a bunch of money... new braided lines all around, all new seals, all new fluid, black braided coverings for the lines, and new pads all under $275... thats a win!

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last night i was able to cut out the turn signal buckets in the fairing... ran into a bit of a hick up. the fairing is not fiberglass, it is ABS plastic! so that will change the game plan for filling in the holes a bit, exp cause i have done a ton of glass work and ZERO abs work hahaha so looks like it is time to learn!

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also going to make a bit of a trim for the swing arm to tie in a bit more blue
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well did not get much done this weekend but every little step forward is a bit more ground covered

new goodyear braided lines came in, could not have them braided, so like every other cable, line, and wire i wrapped this with expandable tubing to keep it clean
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cut some quick brackets to add some lower support
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and then took some time to plan out how i am going to pull off these fills on the ABS
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tomorrow i am going to get the white paint all stripped off this sucker, and start laying some glass!
 
spent some time making dust this weekend when i could sneak away

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then started the fills
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came out great! just a bit of filler and block, then primer and they are gone

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more parts are starting to roll in... got my 11.8 touring rotor (yes i know my stock is a 11.8) i just hate the look of the dinner plate rotor and wanted it to flow a bit better with the rear rotor. Also the brembo front caliper came in. I also ordered a 2 piece rear caliper and bracket so that it will make brake pad changes, tire changes quicker and easier with the powder coated wheels. also i can now powder the caliper in blue and then the mount gloss black so it vanishes. picked up some stock for a fill plate i am making on my swing arm. slowly but surely every day i try to do at least 1 thing

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well this weekend i was able to get the inner fairing backing plates glassed in

used some blue tape, went over that with duck tape, waxed it so that the glass would not stick and would lift off

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also picked this up for the lake house
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and scored a great deal on a new 140c lincoln mig
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had a few hours so i did some more glass! fairing is done till i can get the mounts welded up and then do the inner speaker pods.

had some broken tabs where the headlight mounts so i had to create new ones, some wax paper, cardboard, tape and glass later, i have what i need just need to shave them out

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also added in another layer of support in the signal locations, then glassed in the joint where the buckets connect as that is what will become my main support and i want as much there as possible

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had to start on the bags as well, first step was to fill the key holes

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all filled and smoooooth

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new wiring under the dash all done, idiot lights all replaced fresh new LEDS, everything is back assembled and ready to rock! also added in a remote line to turn on and off my fairing electronics/stereo.. to remove the ring you have to work it off all around, then you can get to the LED board. From there assembly is in rev. We will be offering this service complete with coated trim ring

i hate how the clip nuts always spin and are a pain in the ass so i tacked some nuts on the dash support

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filled some more holes and started to shape the tabs for the trim mount

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not sure if i am going to polish this, or go blue. but i am using the stock adjustment hole that i tapped to help mount it, next winter ill drill holes, slug it with pipe, and weld it all up when i coat the frame and swing arm
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ok... well we have been super busy in the shop so i did not get much done... but here is a shot of the monroe air shocks painted in gloss black to clean them up... the metal was really rough so i used a flap wheel to clean it all up, then i lightly blasted them, then painted them, masked off the bellows area for both. also finished up the swing arm trim (tossed some blue tape on it to give me an idea on looks) and then tacked the inner fairing support mounts after i cut the plates to fit what i need

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please excuse the mess... but last night spent a bit of time on the bags, trying to get them as close as possible. so i cut the bags and put the brackets on the inside of them, now i just need to weld up a plate on the inside mounts and make it all one piece. look how much tighter it gets the bags into the bike!

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spent some free time on the bike this weekend. i actually got enough done where i could bring some stuff into the shop with me and work on them while we where between jobs on customer stuff. Also Tim was able to do a bit of welding work to help speed things along. Man i forget how nice working on my own stuff in our shop is! hahaha

shaved the calipers
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the brembo had a stamp in it
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added some weld
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ready to be blasted and powder
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rear all feathered in and ready to go
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also shaved a set of levers
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all finished and clean ready for powder
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i hated my back section of the floor boards i was always worried i would burn my boot on my pipes and to be honest i wanted to be able to just put my heel in and relax... so made something

bent some round stock to match the shape

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welded that up
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will work great
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finished the rest of the swing arm trim

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both sides are done now and ready for powder

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then started to work on the new inner saddle bag supports, have that all tacked up till i can fab up some additional supports
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laid a heavy MIG weld as they will not be seen and i wanted support and strength

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well keeping up with my do one thing at least a day... i got my new storz steering damper in! I am so stoked to ride with this sucker... i also got bike side of my wire harness done fro the fairing.

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sorry for the poor pics, ill get some more later. by the time we finished up customer stuff and I was able to do some of my own it was 2am and i did not get home till 4am. i was beat to take pics

swing arm trim and saddle bag trim all done

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shaved and powder coated brembo looking great!!!
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got almost nothing done yesterday but had to get at least 1 thing done... so installed my coated swing arm trim

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Thank you sir! how is that HD treating you?


ooh yes look how sick these came out! so glad i took the extra time to shave, welded up, final shaping shave, coating, and soon to be freshly rebuilt

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