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Author Topic: Norton / Harley Ironhead Cafe Project.. Build thread  (Read 72644 times)

Offline o1marc

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #30 on: Oct 17, 2013, 15:04:02 »
Did you bother to weigh the POS you started to compare with the new ride? Interesting build and fee structure over there. Would certainly prevent some from starting from scratch.


Offline o1marc

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #32 on: Oct 17, 2013, 16:09:31 »
Kool project, marc you taking notes
Why would I need to take notes?

Offline bradj

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #33 on: Oct 17, 2013, 16:50:47 »
Becouse his parts are all researched and will work together. You just bought stuff to brag about.

Offline Bevelheadmhr

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #34 on: Oct 17, 2013, 16:55:02 »
Did you bother to weigh the POS you started to compare with the new ride? Interesting build and fee structure over there. Would certainly prevent some from starting from scratch.

No I didn't weigh the original bike, but specs say it weighs approx. 525 lbs. I'm aiming to lose 100lbs. I have weighed the OE frame, wheels, forks etc, and the new equivalent parts. So far lost 73lbs and should get close to my target by the time the exhaust, electrics are done. I have cheated a bit as it wont be getting mirrors, rear pegs and so on. 

Here are some examples of old Vs new part weights (in lbs)

                                          OLD         NEW
Frame/SA                             53            34
Front wheel/tyre/discs           31            29
rear " " "                              38.5         30.1
rear fendor/seat                    10.5          2.7
oil tank                                   7             2.3
tank                                       7.5          6.5
front fender                            3             0 (not having one)
footpegs/controls/mounts      16             2.9
rear brake caliper/mount         5.7          2.3
Forks/yokes/calipers             36            31
Rear shocks                           8.4           7
Bars / risers / grips                5.5           1.8

Offline WeberKid

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #35 on: Oct 17, 2013, 17:06:00 »
awesome project!

Offline Bevelheadmhr

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #36 on: Oct 17, 2013, 17:06:05 »
I'm getting almost up to date now, at last it was on its wheels and I could sit on it and make brum brummm noises when no one was looking  ;)

Still needed to sort out the wheel spacers and a brake caliper for the rear wheel, but bodged a couple of spare spacers I had for now. Then I had one of those strange incidents that leave me baffled.. I knelt down to fit the front wheel, trying to line up the spindle with the first spacer, and the spacer fell to the floor.. need three hands for this job.. I fished around for the spacer, couldnt find it. I stood up, had a look around my feet, no spacer. I had a good hunt around, no spacer, I moved everything in the blooming room, no spacer.. god knows where its gone, it only fell a foot, so it could hardly have bounced off somewhere.. must have a black hole in there, its the only explanation. I'll have make another, in the meantime another spare spacer was bodged on.


At least I didn't lose this cool replacement choke 'enrichener'.. since I wont be using a standard teardrop S&S air filter with its choke lever, this little gizmo takes its place..

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Offline Bevelheadmhr

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #37 on: Oct 17, 2013, 17:09:33 »
I cut out the shape of the reverse cone megas I'm thinking of buying, just to see how they might look.. I need to decide between high level XR750 style or traditional low level, one either side style????
HIGH

Or LOW

 
I finally went for the classic low level option, as the high level pipes would toast my leg even with heat shields. One easy job was to make an undertray to sit beneath the seat hump, as that's where most of the electrics will be going. So I cut up a cereal box to make a simple template..

 
I made it longer than expected, so I can use it to mount the seat a little further forward if needed, I can always cut it back a little to look neater. Then to save myself a lot of hassle, I went over to a local fabrication workshop (best welder in town) who is happy to make stuff for me for a few quid cash in hand. When he isn't on site working at places like Kellogs and Heinz, he works out of a small place in an old converted barn..
 


 
Where he soon made me the tray in 1.5mm stainless plate, all I had to do was bend it slightly to follow the lines of the seat loop when I got home. Just need to drill a few mounting holes and sort out some kind of P clips to support it at the back. I don't want to weld any tabs onto this frame, its too nice to mess up.
 


Offline o1marc

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #38 on: Oct 17, 2013, 17:11:12 »
Do you have a more intensive build thread elsewhere?

Offline Bevelheadmhr

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Re: Norton / Harley Ironhead Cafe Project.. Build thread
« Reply #39 on: Oct 17, 2013, 17:14:48 »
I sat down the one evening and listed all the jobs and parts I still needed to finish the bike.. it came to 3 pages of A4 .. oh well, best keep going then.
 
I ordered a few more parts, big 7 inch headlamp, ignition barrel, tail light etc. The tail light is a bit of a cliche perhaps, but I like it. need to make a mount for it now and for the number plate too.. Ill add it to the list.

 
Next I fitted a Tomaselli throttle and grips, it will need a one off cable to work with the S&S carb, that can wait for now..

 
Next my plan for a hydraulic clutch conversion is going ok, had to use a Banjo bolt with a built in bleed nibble for the slave cylinder. It sticks out a fair bit from the case and looks as if it'll need some kind of protection in case its gets knocked or the bike falls over (fingers crossed it never will). I need to work out how long the clutch rod extension needs to be to work with the slave cylinder.. another item to add to my list..
 
Old Bembo slave cyinder on the left, we used its piston and seal in the new one..

The one off slave replaces the clutch inspection cap in the Primary cover

I tried a few calipers I had, all Brembos, a couple from a 916 and one from a CB500. None really worked how I wanted, so I ended up buying a new rear caliper at a very good price. I'll take the swingarm and wheel to Jeff workshop and make the wheel spacers and a caliper mount. It means the bike will have two black front calipers and a gold rear, which bothered my OCD tendencies a little, till I noticed that a BMW 1000RR has gold front Brembos and a black rear, so if its good enough for BMW its ok for me..

 
Shiny new caliper.. need to make a mount, torque arm and wheel spacers next..