DO THE TON

Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: 3DogNate on Oct 08, 2017, 13:29:57

Title: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 08, 2017, 13:29:57
So I sold off my BMW R75 and I scored this really clean and good running 2005 Sportster for a really great price (below trade val) with a bunch of extra seats, bags and stuff. After I sell off the stuff I'm not going to use this donor will be downright cheap. Now... I'm a fan of the Sportster as a platform... I've built hard tails and cafe bikes so those are no bueno. I'm going to make this bad boy into a sweet scrambler. 

This is what I brought home
(https://farm5.staticflickr.com/4490/23704316198_c92a178b79_k.jpg) (https://flic.kr/p/C7EPmS)Sportster beginnings (https://flic.kr/p/C7EPmS) by Nathan Noel (https://www.flickr.com/photos/152165602@N02/), on Flickr

Here it is after some de-farkle-ing...
(https://farm5.staticflickr.com/4461/36886677543_9fafbb6b93_k.jpg) (https://flic.kr/p/YcxS82)Sportster beginnings (https://flic.kr/p/YcxS82) by Nathan Noel (https://www.flickr.com/photos/152165602@N02/), on Flickr


Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 08, 2017, 13:34:10
The plan:
My intentions are to make this guy a capable scrambler.... Here's a first pass punch list

Front End
* New Wheels
   - Silver Excel Rims (18x3.5 Rear / 19x2.5 front)
   - Stainless Spokes
   - Charcoal Powder Coated hubs (new bearings)
   - New Bearings

* Heavy Duty Progressive Fork springs
* Bronze Powder Coated Fork lowers
* Charcoal Powder Coated Triple Trees
* Short Risers (charcoal)
* Relocated Speedometer (RSD Cafe Mount)
* Bronze Headlight bucket (LED headlight with integrated LED Turn signals)
* Tracker Bars
* Stock Controls
* Gaiters
* Dual purpose tires


Rear End
*15" Hagon shocks
* Chain Drive
* Modified fender
* Custom seat
* Strut removal

*

Other
* Mid Controls
* Peanut tank
* Bronze and Charcoal engine powder coating for a dark look but NOT BLACK
Spring
* New paint TBD
* RSD Scrambler exhaust (Or custom if i can muster it.)

* If I can tackle the engineering I would like to add adventure bike style aluminum or pelican pannier bags.

Custom fabrication where ever I can fit it in
*

Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: doc_rot on Oct 08, 2017, 15:37:59
sweet. im in
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 08, 2017, 16:20:40
I scored a good front hub off ebay and cleaned it up and powdered it in the Charcoal PC and installed new bearings. This will be the minor color in my two color powder coat theme... (along with some stock black that I don't plan on changing out. Rear hub should be here Tuesday, I'll get it rebuilt and  call up Buchannan and order my hoops and spokes and get the wheels off to my lacing guy so I can get the wheels done. I've had to add a new chock to my lift to accomodate the sporty, i've gotten along with other bikes with center stands up to now... the Harley is a little harder to deal with on the lift. the new chock does a great job though.

(https://farm5.staticflickr.com/4487/37528638876_7fda9671cb_k.jpg) (https://flic.kr/p/Zbh5RS)Powder coated sportster hub (https://flic.kr/p/Zbh5RS) by Nathan Noel (https://www.flickr.com/photos/152165602@N02/), on Flickr
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 08, 2017, 19:13:07
I started the breakdown today... gonna try to get the front end broken down and rebuilt this week... lot of powder coating to do. Cables are in good shape, they'll need to be shortened though

(https://farm5.staticflickr.com/4475/37548326762_5d8861e840_c.jpg) (https://flic.kr/p/Zd1Zob)Underway... officially (https://flic.kr/p/Zd1Zob) by Nathan Noel (https://www.flickr.com/photos/152165602@N02/), on Flickr
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 1fasgsxr on Oct 09, 2017, 11:58:03
I'm in !
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: WhyNot on Oct 09, 2017, 16:04:00
Me 2.....

Nice bike to start with..............
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: killerx on Oct 10, 2017, 11:12:39
This should be interesting.
I will be watching.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: irk miller on Oct 10, 2017, 11:19:17
Happy to join the fun.  I've never been of the HD ilk, but this Cycle World article about the El Solitario builds that came out this summer really shows the potential in these...

https://www.cycleworld.com/el-solitario-desert-wolves-custom-harley-davidson-sportsters-desert-adventure?src=PPC1&dom=fb&con=Keywee&lnk=FB14&kwp_0=535195&kwp_4=1949429&kwp_1=817300 (https://www.cycleworld.com/el-solitario-desert-wolves-custom-harley-davidson-sportsters-desert-adventure?src=PPC1&dom=fb&con=Keywee&lnk=FB14&kwp_0=535195&kwp_4=1949429&kwp_1=817300)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 17:36:12
I broke down the forks last night. I'll blast and powder coat the sliders tonight and get those rebuilt. I stopped by my wheel guy's shop and ordered the Excel hoops and spokes. I decided to go with Metzler Tourance tires for a bad ass looking, good all around tire with a preference for the road. Should have those built in the next week or so... he's crazy fast. I gotta get my hubs to him in the next couple of days.
(https://farm5.staticflickr.com/4457/37567144466_57e706a4ef_k.jpg) (https://flic.kr/p/ZeFrem)Forking around (https://flic.kr/p/ZeFrem) by Nathan Noel (https://www.flickr.com/photos/152165602@N02/), on Flickr
(http://www.metzeler.com/site/com/mediaObject/MetzelerSite/CommonImg/Product/Tyres/Tourance/product_sheet_tourance_460x500_jpeg/original/product_sheet_tourance_460x500_jpeg.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 17:42:36
Happy to join the fun.  I've never been of the HD ilk, but this Cycle World article about the El Solitario builds that came out this summer really shows the potential in these...

https://www.cycleworld.com/el-solitario-desert-wolves-custom-harley-davidson-sportsters-desert-adventure?src=PPC1&dom=fb&con=Keywee&lnk=FB14&kwp_0=535195&kwp_4=1949429&kwp_1=817300 (https://www.cycleworld.com/el-solitario-desert-wolves-custom-harley-davidson-sportsters-desert-adventure?src=PPC1&dom=fb&con=Keywee&lnk=FB14&kwp_0=535195&kwp_4=1949429&kwp_1=817300)

It's unfortunate that people that can't buy into "Harley Culture" dismiss their bikes. You can enjoy a Harley-Davidson without being a Biker. They are absolutely wonderful motorcycles. The Evo Sportster is bullet proof, nimble, with a  little effort can be really quick.  My 2017 Road Glide Special is a spectacular touring bike.

But follow along... this build will be fun...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: SONIC. on Oct 10, 2017, 18:04:15
I like it.
I'm in.

I agree on the culture crap, but hey they brought it on themselves.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 18:55:32
I like it.
I'm in.

I agree on the culture crap, but hey they brought it on themselves.
Well, to be honest with ourselves...  they have built one hell of a brand name.  They don't mind a little dissing from the Never Harley crowd.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: irk miller on Oct 10, 2017, 19:43:43
Dude, seriously?  I'm not against HD.  I just don't like the style of most Harleys.  I don't like V-twin Ascots.  Does that make me part of the Never Honda crowd?  I don't want to pay what people want for a Harley.  I could give a fuck about Harleys or Harley culture.  Have fun building your half ton Scrambler.  Dammit.  Now I regret joining this thread.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 19:56:29
Dude, seriously?  I'm not against HD.  I just don't like the style of most Harleys.  I don't like V-twin Ascots.  Does that make me part of the Never Honda crowd?  I don't want to pay what people want for a Harley.  I could give a fuck about Harleys or Harley culture.  Have fun building your half ton Scrambler.  Dammit.  Now I regret joining this thread.

I love all motorcycles... Honda, Triumph, Yamaha, Ducati, Harley, Indian, Moto Guzzi, Suzuki, BMW, Kawasaki,Norton, BSA... I can get on board with bashing Russian, Chinese and Korean brands though... they haven't gotten their shit together.

After my CB360 build... I'm offically in the Never CB360 crowd...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 20:17:26
Fork Sliders are cooking... can't wait to see how this bronze powder turns out.

(https://farm5.staticflickr.com/4446/37625143371_675ca73fce_b.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: irk miller on Oct 10, 2017, 20:27:33
I love all motorcycles... Honda, Triumph, Yamaha, Ducati, Harley, Indian, Moto Guzzi, Suzuki, BMW, Kawasaki,Norton, BSA... I can get on board with bashing Russian, Chinese and Korean brands though... they haven't gotten their shit together.

After my CB360 build... I'm offically in the Never CB360 crowd...
Haha.  I had to dive in for a second CB360, man.  I have a special hate for myself. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 21:06:25
Haha.  I had to dive in for a second CB360, man.  I have a special hate for myself.

If you are in for that kinda punishment... you can hang around for a hopped up, not a chopper/bobber/brat/cafe Harley.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 10, 2017, 22:07:13
So the fork sliders came out good... I did the sliders in bronze and did the caps in charcoal... I'll have gaiters on the bike so you'll not see the caps... but it's good attention to detail. The plan is to do the engine covers and rocker covers in the bronze with a little bit of charcoal tossed in... can't wait to see that all done.

(https://farm5.staticflickr.com/4504/37367587890_bf93c08e1f_b.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 11, 2017, 23:54:29
I finished disassembling the front end today media blasted the yokes, speedo-housing and riser clamps for powder coat. I'll get those done tomorrow after work. Oh and finished rebuilding the forks with the heavy duty Progressive springs. the new bars will be quite a bit  lower and forward than the old bars. I'm hoping that any extra wire length can be tucked away. if not I'm going to have to do a good bit of wire shortening, not a big deal but hours boring work.  Discovered just how filthy the carb was on this thing too... (outside). I'm shooting to have the suspension, front end and wheels done asap so that stuff will be done before it gets cold. I'll work on fabricating the rear end and tins over the winter along with motor work. BRAAAAAP!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 12, 2017, 21:03:33
Got the trees, risers, and speedometer mount powdered tonight.
(https://farm5.staticflickr.com/4448/36992122273_ea134db368_b.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: canyoncarver on Oct 12, 2017, 21:55:00
Nice to see a sporty build going. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: spotty on Oct 13, 2017, 01:19:28
spectacular work on the PC, inspiring me to have the garage (when it gets built) wired for an oven and spraybooth , as well as the beer fridge and all the other essential needs
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 13, 2017, 09:16:40
Thanks guys... I'm pretty happy with how its heading. I put the yokes and forks together last night and I'm not digging the short Harley risers with the single top clamp. I ordered a set of 1" risers. That'll look better I think.

Spotty... I use a PC gun from Eastwood and toaster oven for small parts, bigger parts go in the upstairs oven. I made a little spray booth in the basement with a squirrel cage fan to keep the PC overspray under control. You'll make back your investment with your first batch of parts. And you seriously can't screw up if you are careful.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 1fasgsxr on Oct 13, 2017, 13:33:16
How are you prepping the pieces for powder ?  I have used a cheap HF gun and got results way better than I ever expected.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: WhyNot on Oct 13, 2017, 14:21:00
Thanks guys... I'm pretty happy with how its heading. I put the yokes and forks together last night and I'm not digging the short Harley risers with the single top clamp. I ordered a set of 1" risers. That'll look better I think.

Spotty... I use a PC gun from Eastwood and toaster oven for small parts, bigger parts go in the upstairs oven. I made a little spray booth in the basement with a squirrel cage fan to keep the PC overspray under control. You'll make back your investment with your first batch of parts. And you seriously can't screw up if you are careful.

Can you post some pix of your setup?

Man those parts look great....
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 13, 2017, 14:24:50
How are you prepping the pieces for powder ?  I have used a cheap HF gun and got results way better than I ever expected.

I bead blast them in an HF bench top blast cabinet. (which I don't recommend if you can support a free standing cabinet... the chute on the small one really isn't steep enough to keep the media down otherwise its great... anyone that mods bikes regular should be doing a ton of their own powder work... it's brainless and requires low effort for good results. I have to take frames, wheels, swing arms, handlebars (most) out to be done. I don't get good results with multi layered PC at home either. So if I want something powdered then candied or cleared... that stuff gets taken to a real powder coat shop. Their equipment is far more capable. But this single color stuff... rock on at home.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: SONIC. on Oct 13, 2017, 18:06:39
Lookin good!

And I agree powder all the way!
 I've done up to 19" wheels, they fit just barely in my oven!

Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 14, 2017, 14:32:39
Got the new RSD LED cluster installed in the Speedo housing and wired into the stock harness... Easy peasy. Next up today I am going to hack up the headlight bucket and weld on a grill to the ring that I scored on ebay, gotta think about the best way to do that.

(https://farm5.staticflickr.com/4466/37023835233_30bcd22f4e_b.jpg) (https://flic.kr/p/YpEQjM)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 1fasgsxr on Oct 14, 2017, 21:23:07
I built an oven from an old small freezer just right for wheels, but I can't get my controller figured out  >:(
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 15, 2017, 10:41:24
I built an oven from an old small freezer just right for wheels, but I can't get my controller figured out  >:(

If I had a big dedicated shop, I'd draw up a plan and have a sheetmetal shop bend me up a the metal for an oven that would accomodate things up to frame size with a rolling rack system for loading. And step up my blasting cabinet a bit too.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: doc_rot on Oct 16, 2017, 04:21:17
one of the awesome parts of sportsters is there is literally no end to the farkles you can buy. That new clock and lights is nice!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 16, 2017, 13:33:53
one of the awesome parts of sportsters is there is literally no end to the farkles you can buy. That new clock and lights is nice!

You aren't kidding... Yeah the speedo housing and LEDs are Roland Sands units... I couldn't get past 'em and had to have 'em... not cheap but groovy and mine are the only ones in that color so... win. I scored a barely used set of Roland Sands pre-load adjusters on ebay for less than half the price of new ones. Which is cool... Also a set of RSD foot pegs... It's unplanned but I'm evidently destined to have a ton of RSD parts on this bike as I'll likely have a Roland Sands scrambler exhaust. I just don't think I'll have the energy to build a set from scratch. My handlebar can't fit in my oven so I had to drop that off at the powder coater this morning. I don't need a flashy piece of chrome jumping out.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 17, 2017, 21:52:45
Nothing to really show off right now... I've sold off most of the major take-offs from the Sporty. Tins, Wheels+Tires and Exhaust all that is really left. Oh and a Stage 1 intake.

But I got a used rear spoke hub off eBay and got that thing powder coated and installed new bearings. (Factory bearing removal was most fussy....)  I was able to drop both hubs off at my wheel guy today, he already had my tires in... should have my hoop/spoke order from Buchanan any day. Got the new risers in also... not sure I like em any better than the others... might stick with the factory risers. Dropped the handlebar off at the PC shop and should have that.... fingers crossed I'll have the front end finished next week and can focus on the rear end.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: JadusMotorcycleParts on Oct 19, 2017, 15:42:25
Love seeing a Sporty being de-cruiserised.  Looking forward to seeing the progress!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: trek97 on Oct 19, 2017, 20:16:30
What you got going on here is looking great bud.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: The Jimbonaut on Oct 20, 2017, 12:34:18
Man I've got a 2000 Sportster Sport edition sitting in my garage waiting for a buyer.  Reading your thread and your plans is almost - almost - giving me second thoughts about pulling the ad!  Will be following your thread with much interest and enthusiasm - looks great so far
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 20, 2017, 18:04:05
Thanks for the props guys.

I swung by the shop and my wheel guy John was busy lacing and truing up my rear wheel and getting ready to start on the front. It's good to have a true old school motor head that has done nothing but work on motorcycles for nearly 50 years. John's the best wheel guy in area for sure. These Excel rims are gonna look and perform awesome... I also have my chain conversion and rear shocks on the way. I went with 15" Burly Stiletto shocks. I have some more powder coating to do this weekend in anticipation of getting the front end done next week.

(https://farm5.staticflickr.com/4463/37786303322_2e658102b2_b.jpg) (https://flic.kr/p/Zz3Fwj)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 1fasgsxr on Oct 21, 2017, 20:37:26
Nothing looks better than spoked wheels imo. Just plain sexy!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 24, 2017, 00:11:19
So I got some more powder coating done tonight while still waiting on some parts and my wheels to arrive.

(https://farm5.staticflickr.com/4459/24040895688_656d978924_b.jpg) (https://flic.kr/p/CCpSHw)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 25, 2017, 15:03:04
My chain drive kit came yesterday and over lunch today I started working on it and got the drive sprocket installed... holy shit man that 1-7/8" nut on the original drive pulley was REALLY on there no way in hell could I break it even with a 3' breaker bar. Had to run out to a nearby pawn shop and buy a pneumatic 1/2" impact wrench.... and that barely got it removed.... geez. I will say one thing... Harley's build quality is absolutely stellar... I've wrenched around on about every major brand and Harley isn't fucking around.

(https://farm5.staticflickr.com/4457/37219926724_04904baf4a_b.jpg) (https://flic.kr/p/YGZRuy)
(https://farm5.staticflickr.com/4452/37219927824_8ce47fc871_b.jpg) (https://flic.kr/p/YGZRPw)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: 3DogNate on Oct 25, 2017, 18:56:17
Got My headlight bucket put back together. We've got a new LED headlamp and a rock protector grill installed. Original bucket in a two tone powder coat.

(https://farm5.staticflickr.com/4514/37224346084_faa47bd12a_b.jpg) (https://flic.kr/p/YHovdq)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: Rider52 on Oct 25, 2017, 19:30:19
I'm really enjoying this build!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build
Post by: Pete12 on Oct 26, 2017, 02:39:31
Wow, great work on the powdercoating. I've had an Eastwood powdercoater for 20 years but never really used any trick colours and combinations like you have - very inspiring, thanks.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on Oct 26, 2017, 13:23:18
is that a "hammertone" color?
Title: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 26, 2017, 14:22:44
is that a "hammertone" color?


It is not a hammertone... it's a 10-15% gloss metallic.

Oh and I got the call that my wheels are ready to pickup after work...  got them home and slapped the discs and sprocket on em.

(https://farm5.staticflickr.com/4445/24102130498_f258e54c76_b.jpg) (https://flic.kr/p/CHPHG7)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 27, 2017, 12:43:43
Started fitting the new wheels up... Gotta wait for the new shocks to arrive before I can cut the chain to length but it lines up perfectly.

(https://farm5.staticflickr.com/4470/37914983556_83d1a171d0_b.jpg) (https://flic.kr/p/ZLqcF3)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Pete12 on Oct 27, 2017, 17:58:38
Nice, very nice. Nothing looks better on a Harley than spoked wheels with alloy rims, in my humble opinion, but surprisingly hardly anyone does it.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 27, 2017, 18:55:10
I got my new Burly Brand Stiletto shocks installed today. I'll get the chain cut to length tomorrow morning. Pic is with the weight on the shocks... no worries about travel... there'll be no bottoming out now in the turns... (Like we have turns in Illinois... )
(https://farm5.staticflickr.com/4451/37921387446_059b95df24_b.jpg) (https://flic.kr/p/ZLZ2jW)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 27, 2017, 18:55:59
Nice, very nice. Nothing looks better on a Harley than spoked wheels with alloy rims, in my humble opinion, but surprisingly hardly anyone does it.

Well.. I'll tell you what... it was NOT cheap to do.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Pete12 on Oct 27, 2017, 19:24:01
Well.. I'll tell you what... it was NOT cheap to do.

Well worth it though.... looks awesome.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on Oct 28, 2017, 08:12:13
I second the spoke wheels !
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 28, 2017, 13:07:29
The build is probably gonna slow down a good bit soon as it's getting cold here and I'll not be able to even think about painting until spring. I did quite a bit really quickly. Punch list is looking like this.

* Cut chain to length
* Setup handlebars and wire in front turn signals (you can see the little LED rings on the forks in the headlight picture. I'll have to add load resistors into the harness.
* Make up front brake line
* Powder coat levers
* Clean and rebuild Carb
* Powder coat engine covers and Rocker covers
* Buy Ironhead Front fender and modify it.
* Fabricate rear fender modifications. (Decisions to make here... cut struts add a hoop, don't cut struts stay mild, )
* Select and order exhaust (gonna be hard for me to not pick the RSD Scrambler exhaust.)
* Paint


Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on Oct 28, 2017, 15:12:40
(gonna be hard for me to not pick the RSD Scrambler exhaust.)

Unless you plan to go with high pipes, pick the RSD Scrambler exhaust.  It's too nice not to. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 28, 2017, 17:22:53
Unless you plan to go with high pipes, pick the RSD Scrambler exhaust.  It's too nice not to.

The more I look and contemplate welding up my own design... the more it's enevitable that I go with the Roland Sands option. It evidently sounds great and is a good performer as well.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 29, 2017, 21:16:41
I got the chain cut to length today. I had to cut off the upper passenger peg mount and belt guard mount off the swing arm. The longer suspension puts the chain right in their path. So there's no way there'll be a passenger, but this wasn't ever gonna be a 2UP bike anyway...  kinda justifies what my tentative plans are for the rear. I have a bit of wiring clean up to do up front and need to add load resistors to the turn signals, they flash way too fast.

(https://farm5.staticflickr.com/4446/37994790172_0190096c1c_b.jpg) (https://flic.kr/p/ZTtepb)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Oct 31, 2017, 00:38:58
I was able to get the footpegs and mounts done today. I ended up turning a new bushing for the brake pedal on the lathe (I melted the original when i was powdercoating... I forgot to remove it. :)) I also relocated my coil to where the horn was mounted... I'll post a pic of that when I get the plug wires shortened. Oh also my original tank and fenders sold so I was able to get my front and rear fenders ordered along with a carb kit... Hopefully my exhaust and wheels sell soon too... I could just about pay for the exhaust or at least knock out the seat also. :) I'm having fun.

(https://farm5.staticflickr.com/4446/38024049212_069cf5669d_b.jpg) (https://flic.kr/p/ZW4c6o)
(https://farm5.staticflickr.com/4452/38001540236_3c13f2abfd_b.jpg) (https://flic.kr/p/ZU4PXA)

Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 03, 2017, 00:14:45
I got my handlebars from the powdercoater today. I think that's gonna work great.
(https://farm5.staticflickr.com/4450/38128632991_f236b7b852_b.jpg) (https://flic.kr/p/216idcZ)

Also my rear fender came so I tossed the tank and seat on along with the new fender to see how stuff looks... def not using that stock seat and I think that fender is gonna get shortened for sure...
(https://farm5.staticflickr.com/4505/38096708522_8a045b260c_b.jpg) (https://flic.kr/p/213tAb7)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on Nov 03, 2017, 13:13:20
its looking good !!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Rusnak_322 on Nov 03, 2017, 14:49:55
The bike is looking good, and I love the dual sportster name. But those pegs look off, it may just be the angle of the pic, but it looks like you would have to angle your toes inward to hit the rear brake or shifter.


Sent from my iPad using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 03, 2017, 21:35:41
The bike is looking good, and I love the dual sportster name. But those pegs look off, it may just be the angle of the pic, but it looks like you would have to angle your toes inward to hit the rear brake or shifter.


Sent from my iPad using Tapatalk

Must be the angle.. they are pretty close to the same shape and orientation as the stock pegs were, like every EVO Sportster mid-controls since '04 when they changed the mounts.

Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: AgentX on Nov 04, 2017, 07:21:31
Seen the Cone Engineering 2-1 for Sportsters?

(http://www.coneeng.com/images/harleyDavidson/harley-davidson-muffler.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 04, 2017, 11:35:16
Seen the Cone Engineering 2-1 for Sportsters?

(http://www.coneeng.com/images/harleyDavidson/harley-davidson-muffler.jpg)

Hadn't seen that one... and it's about the same price as the RSD one but stainless.... I was hoping to do a high pipe 2-1. but that certainly doesn't suck. it's on the  list thanks.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 04, 2017, 16:25:37
Got the levers, shock eye covers and coil relocation bracket powder coated today. I ordered a Kinetic Cycles relocation bracket, wasn't terribly impressed with it. The paint they used was brittle and chipped EASY... and the little choke bracket was too wide... so I cut off the choke bracket and fabricated another that fits the choke cable mount much better and powder coated it. At least the KC mount was one of the more affordable ones out there. Oh... and those enormous butt ugly grips are outta here as soon as I pick something.. they feel like I'm holding a leather soda can.

(https://farm5.staticflickr.com/4462/37459049044_f6fa86a08c_b.jpg) (https://flic.kr/p/Z58qeb)
(https://farm5.staticflickr.com/4566/38169342261_8ae5afd76f_b.jpg) (https://flic.kr/p/219TRDX)
(https://farm5.staticflickr.com/4447/38113368856_945855eac6_b.jpg) (https://flic.kr/p/214WYHf)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: AgentX on Nov 05, 2017, 08:29:47
leather soda can.

Euphemism of the week...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 05, 2017, 09:32:47
Euphemism of the week...

LOL ::)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 05, 2017, 13:56:12
Well piss... turns out that my front tire ended up being just a wee bit too fat to be able to use the Ironhead style fender struts I was hoping to... Now I'm on the hunt for a Nightster/72 type fender...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 10, 2017, 23:31:33
Gonna give a swing arm chain tensioner on this one a go... that'll keep the chain off my rear brake linkages.  I need  to do some upgrades with a skateboard wheel and possibly a stronger spring but it's physically gonna work.

(https://farm5.staticflickr.com/4583/24425949168_ff1b46691f_b.jpg) (https://flic.kr/p/DdrnGC)

I also grabbed some matte black mirrors off eBay....
(https://farm5.staticflickr.com/4545/38241930316_2e91425e8a_b.jpg) (https://flic.kr/p/21giTy9)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 12, 2017, 15:49:25
I relocated my coil over to where the old horn was mounted. I got out and installed a smaller horn up in the front today. (no way can my OCD allow for a horn button and no horn.) I'll probably fabricate a better bracket that tucks it up a little tighter.
(https://farm5.staticflickr.com/4571/37654361644_93470aa535_b.jpg) (https://flic.kr/p/ZnorRN)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 13, 2017, 23:24:48
I finished rebuilding the carb last night... I re-jetting it with new brass and needle from CV performace and added an extended Mix screw so that I might actually reach it to tune it. :)

I added a metal cap to it... I'll powder coat it to match the intake and other stuff if the stinkin' intake would ever show up.

(https://farm5.staticflickr.com/4515/38405359701_ec5c1100f7_b.jpg) (https://flic.kr/p/21vKvqa)

My new grips arrived today too... MUCH better than the huge leather grips that were on it.

(https://farm5.staticflickr.com/4578/38350257916_67f0e21100_b.jpg) (https://flic.kr/p/21qT6zo)


30 minutes a day... chiseling away at it...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 15, 2017, 19:58:50
New steering stem bolt.. the old one was fugly cause it was hidden before I switched risers.
(https://farm5.staticflickr.com/4520/37558424815_c434216940_b.jpg) (https://flic.kr/p/ZdUKbx)

My Nightster fender arrived today and I did a quick fitting and all is good. I might add a fender extension for more of that "ready for muddin'" look.
(https://farm5.staticflickr.com/4533/24573923408_b1f5c00b89_b.jpg) (https://flic.kr/p/DrvMhC)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 19, 2017, 20:54:32
Started laying out some options on chopping the rear fender down...
(https://farm5.staticflickr.com/4522/26752286939_a491cbe1f2_b.jpg) (https://flic.kr/p/GL1sSx)

Ended up looking like this... I'll get the struts cut and make a decision on if I'm going to trim up the fender any more.
(https://farm5.staticflickr.com/4520/24658653338_af4209d41c_b.jpg) (https://flic.kr/p/Dz13xu)

and yes.. my lift is a pig-sty...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: DBrevit on Nov 20, 2017, 16:26:48
I thought you were building a scrambler, short short fenders in mud ?,
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 20, 2017, 16:40:08
I thought you were building a scrambler, short short fenders in mud ?,
Itís still extended past the axle a wee bit... should be plenty good enough for all but extreme riding which will never happen... not like weíve got dunes or mountains to play on here in central Illinois.  I donít expect a big old mud streak up my back as it sits. What Iím thinking about for my tail light and license plate might end up extending the mud catcher a little bit anyway. If it doesn't work well I can weld the struts back on and put a full fender back on it... I'm my own paint guy... the expense would be negligible.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 21, 2017, 21:38:05
I did a test fit of the air cleaner today... It's a Chinese cleaner off Ebay, but I swear the machining is as good as any out there... The fit is good and at $30 shipped it's ridiculous that they can even do it at slave labor costs.... I'll powder coat it to match the rest a little later when I'm doing the engine covers. It'll do nicely.

(https://farm5.staticflickr.com/4564/24700064698_0f5ef506b8_b.jpg) (https://flic.kr/p/DCEhGs)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 25, 2017, 00:27:47
I managed to drag myself out to the garage and make up a custom length brake line... I love these BYO Brake line fixtures from Magnum.

(https://farm5.staticflickr.com/4560/37907306144_fbe8564870_b.jpg) (https://flic.kr/p/ZKJRrS)
(https://farm5.staticflickr.com/4574/24752187778_7c9ab4df07_b.jpg) (https://flic.kr/p/DHgr5f)

Here's a profile pic with the tank sat upon it.
(https://farm5.staticflickr.com/4566/38592269322_ee28437603_b.jpg) (https://flic.kr/p/21Ngt8Q)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Pete12 on Nov 25, 2017, 17:54:02
I managed to drag myself out to the garage and make up a custom length brake line... I love these BYO Brake line fixtures from Magnum.

Wow, I'd never heard of this company, thanks for the tip. I'm going to order some for my 450.
Your bike is coming along really well, btw.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on Nov 25, 2017, 18:03:04
Wow, I'd never heard of this company, thanks for the tip. I'm going to order some for my 450.
Your bike is coming along really well, btw.

I built the brake line for Rachels CB400a - custom lengths and fittings sold individually from 4into1.com.
And yes Nate she's really shaping up to be something awesome.
Did you buy spokes and hoops from your wheel builder?  Id like to put shouldered hoops on the Cherry Bomb.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: SONIC. on Nov 25, 2017, 19:02:40
Looking good.
Do you have enough suspension travel to warrant that fender? It is really going to limit your options for a good looking seat. I assume you lifted the rear, could you lower the fender by a few inches?
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 25, 2017, 23:46:12
Looking good.
Do you have enough suspension travel to warrant that fender? It is really going to limit your options for a good looking seat. I assume you lifted the rear, could you lower the fender by a few inches?

It's a stock Nightster/48 style fender that I cut down and mounted stock style so it's not weirdly proportioned. The shocks are 15" Burly Stilettos (2" longer than stock)... so there's additional travel over stock... I'll not know what kind of pre-load I'll have on the rear until I ride it.

There are plenty of seats that'll look great on here..
Roland Sands Boss solo
(https://scontent.cdninstagram.com/t51.2885-15/e15/10593415_1587487331535284_259953907_n.jpg?ig_cache_key=OTU2NjQyMjIzMTk2MzgzMDY2.2)

Roland Sands Enzo Solo (1st choice at the moment.)
(https://www.rolandsands.com/assets/images/products/0804-0439-RSD-Solo-Seat-Sportster-Enzo-1.jpg.ashx?format=jpg)

Biltwell Speedway
(https://3b0b747a213bc007f504-201cd9801cfd61c625913545c1a472ef.ssl.cf1.rackcdn.com/images/products/detail_373_1467928188__speedway_tuck_web3.jpg)

Mustang Tripper
(https://img.jpcycles.com/zoom/802-948_A.jpg)

Saddlemen Knuckle Solo
(https://i.ebayimg.com/images/g/AWQAAOSwb9dZwaxf/s-l500.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Nov 26, 2017, 18:19:05
So I pulled the trigger and sliced off the fender struts... happy. Cut them off with the Sawz-all and cleaned up the cuts and shaped them with a flap wheel. Then turned around and hit them with a shot of black epoxy paint.
(https://farm5.staticflickr.com/4537/24791965898_cc05eafbde_b.jpg) (https://flic.kr/p/DLMiHU)
(https://farm5.staticflickr.com/4522/37946411774_1b4d48a0f6_b.jpg) (https://flic.kr/p/ZPchbS)
(https://farm5.staticflickr.com/4578/38608115376_a72dc4fe39_b.jpg) (https://flic.kr/p/21PEFBE)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Dec 03, 2017, 00:32:15
So I got out this weekend and fabbed up a tail light / license plate mount and got them welded to the rear fender. i'll be using a football shaped run/brake/turn light that I got off ebay... it'll look great when it's all done. I'm totally an amateur welder but this turned out pretty good I think.

(https://farm5.staticflickr.com/4567/38082431924_8eaa734d7f_b.jpg) (https://flic.kr/p/212dqeS)
(https://farm5.staticflickr.com/4561/23933982777_e823b06c5e_b.jpg) (https://flic.kr/p/CsXVet)
(https://farm5.staticflickr.com/4572/27023273019_1ab4ddeb25_b.jpg) (https://flic.kr/p/HaXkAk)
(https://farm5.staticflickr.com/4542/27023273469_e34cf9d78a_b.jpg) (https://flic.kr/p/HaXkJ6)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Dec 03, 2017, 02:01:20
Nicely done!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Pete12 on Dec 03, 2017, 02:04:58
Great job, this bike is coming together really nicely.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Dec 05, 2017, 22:10:27
Here's what the rear looks like with the tail light and tag installed.
(https://farm5.staticflickr.com/4519/38862643791_8a2f70575d_b.jpg) (https://flic.kr/p/22dad3B)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Dec 06, 2017, 11:17:19
Looks great.  Sweet plate.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Dec 06, 2017, 11:47:22
Looks great.  Sweet plate.

Thanks but that's just a Photoshop job on the plate to hide my real plate.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on Dec 06, 2017, 13:24:51
best photo shop Ive seen in a while.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Dec 06, 2017, 15:19:27
Thanks but that's just a Photoshop job on the plate to hide my real plate.

Lol.  I knew something was different but didn't count the letters.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Dec 16, 2017, 00:46:05
Here's my annual "I hate the fuckin' cold weather" post... f'n Illinois winters... GRRRRRR
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: doc_rot on Dec 16, 2017, 02:00:24
Here's my annual "I hate the fuckin' cold weather" post... f'n Illinois winters... GRRRRRR

I almost went to grad school in Chicago, when I was visiting for my interview it was -8, and that alone made me decline the invite.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on Dec 16, 2017, 07:08:04
I almost went to grad school in Chicago, when I was visiting for my interview it was -8, and that alone made me decline the invite.
Ha! I had a similar experience at U of Illinois.  It was early April, and I opened up my hotel room curtains to snow.  It was in single digits that day.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jan 13, 2018, 16:53:48
Been a little while since I've made an update. But I broke down and chose a seat, I chose the Roland Sands Boss Solo seat. It arrived a couple of days ago. So I fired the heater up in the garage and got it fitted. I had to use a little finesse on the fender to get a good fit... a bit of hole re-drilling, I'll have to weld up the old holes before body work in the spring... But I dig how it looks, think I chose wisely... (the RSD seats are made by Mustang, so I expect it to have good function on top ok looking good.)

(https://farm5.staticflickr.com/4767/39641506752_19a7fae5a0_b.jpg) (https://flic.kr/p/23oZ5Sm)
(https://farm5.staticflickr.com/4630/38963290674_dcf0c2639e_b.jpg) (https://flic.kr/p/22n43RG)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Rider52 on Jan 13, 2018, 21:10:28
Seat looks great! 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jan 28, 2018, 23:55:22
I sold off the remaining take offs from the donor bike and was able to get my exhaust ordered. As a bonus, we've had a couple of days of warmer weather  so I got out in the garage and got the chrome bits on the exhaust powder coated along with the intake. I also removed the engine covers and cleaned them up for powder... Chrome is such a pain in the ass to media blast in my puny little cabinet, I'll take those out to the powder coating shop and let them take care of those. The front cylinder's exhaust cam came out with the timing gear cover... :( hoping to be able to get that back in correctly with out having to pull the head. If I have to pull the head I'll do them both so that I can powder the push rod tubes... But here's the powdered parts for today.

(https://farm5.staticflickr.com/4701/39248079504_166805d04b_b.jpg) (https://flic.kr/p/22NdEDW)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on Jan 29, 2018, 00:43:15
So nice bud.  I need to get over to see you soon.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jan 29, 2018, 14:43:19
So nice bud.  I need to get over to see you soon.

Indeed... plan on riding that K bike up sometime... Some friends and I go ride out to the Black Dog Smokehouse in Chambana occasionally... maybe I can get you to meet up for some of that good hipster BBQ they are pushing... (Love that place.)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jan 30, 2018, 15:51:41
Dropped off the engine covers off at the powder coater's today at lunch.... that's the last of the powder coating (Well... at least the stuff I'll have to source out. There's still not much left.)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 04, 2018, 21:38:53
I pulled the rocker boxes off today so that I could powder coat them. Just can't bring myself to leave them chrome. Now I gotta decide if I'm gonna go ahead and pull the heads so that I can also do the push rod tubes and bases. They will be the last of the chrome items on the bike... kind of a pain in the ass but might just be worth it to lose the last of the chrome bits. I'll get these media blasted, masked and powdered in the next day or two.

(https://farm5.staticflickr.com/4626/40056190742_a3199e9060_b.jpg) (https://flic.kr/p/242CrYj)

(https://farm5.staticflickr.com/4611/25216807477_a5d5ab8533_b.jpg) (https://flic.kr/p/EqjJjH)

(https://farm5.staticflickr.com/4756/39377727144_37260cd00d_b.jpg) (https://flic.kr/p/22ZF9o5)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 06, 2018, 22:32:57
Got a set of Andrews N4 cams on the way now....


Sent from my iPhone using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: The Jimbonaut on Feb 07, 2018, 16:03:25
Dude, such a nice looking sporty.  Sold my 1200 last year without too much regret, but seeing builds like yours definitely gives me a few pangs of seller's remorse!  Love the rear fender chop, the choice of seat, but above everything else I love the bronze powdercoat.  Man, looking forward to seeing this all finished up.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 09, 2018, 20:09:05
New Cams.. Giggity!
(https://farm5.staticflickr.com/4621/25303505697_22a0a1b0c7_b.jpg) (https://flic.kr/p/ExZ5FB)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 09, 2018, 20:54:58
Dude, such a nice looking sporty.  Sold my 1200 last year without too much regret, but seeing builds like yours definitely gives me a few pangs of seller's remorse!  Love the rear fender chop, the choice of seat, but above everything else I love the bronze powdercoat.  Man, looking forward to seeing this all finished up.
Thanks... I'm going to pull the heads off and go ahead and powder the push rod tubes and tappet covers this weekend in anticipation of getting my stuff back from my powder coater... that'll eliminate all chrome...
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 10, 2018, 19:16:16
So, I nutted up and pulled the heads and powdered up the Push Rod Tubes and bases. The inner head bolts were rusty and gross, so I blasted them and stripped the zinc off in some muriatic acid and re-plated them in nickel-copper-nickel. (See my Triumph build for details on that.) This at least gave me the opportunity to check out the cylinder bores which look great. I've been tempted to add a 1275 kit on it and bump the displacement up a bit.... It'd be about $1100 for the Hammer 1275 jugs and pistons, ignition module and re-jetting the carbs. I'm having a conflict on whether or not I can justify it... I'm still in this bike a at pretty decent price even after everything so far. Maybe I'll sit on it a week and think about it....that'd put me around a 90hp bike which is pretty quick for a sporty. Decisions, decisions...

(https://farm5.staticflickr.com/4622/40189625751_27be3d1c4f_b.jpg) (https://flic.kr/p/24eqkxV)
(https://farm5.staticflickr.com/4626/39481106264_c6f0c59053_b.jpg) (https://flic.kr/p/239NZoG)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Feb 12, 2018, 11:59:45
If there's a vote, I vote for the 1275 kit.  :)  You already have the heads off and it'll be more work to do it later.  You know you want to....    ;)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: coyote13 on Feb 12, 2018, 13:00:16
As far as $/hp, if your bores still look good at 1250 I'd stay there.  25cc isn't gonna net you a whole helluva lot for $1100

Edit: new cams should keep you happy for a while anyways  ;)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Feb 12, 2018, 13:58:41
If it's already at a 1250, I missed that.  I was thinking it was an 883 for some reason.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Feb 12, 2018, 16:23:56
I agree, spend that money on some other performance mod, like porting maybe, 25cc is nothing, unless you are racing and need every last little bit of hp.
Title: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 12, 2018, 18:39:41
Itís a 1200. So 75cc more if I do the kit. Weíre talking a noticeable HP difference. The bike has 27,000 miles (which is not a big number on an evo motor)


Sent from my iPhone using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Feb 12, 2018, 20:07:45
The Hammer kits look pretty nice.  I'd only noticed the S&S kits before. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 12, 2018, 20:57:11
The Hammer kits look pretty nice.  I'd only noticed the S&S kits before.

I've got a buddy with a Hammer 1250 top end... he had them do his heads and everything. I think the "Smash" service.. and he's busting a a solid 110+hp... that bike is a beast of a sporty and Hammer is getting even more with the 1275 jugs. (That bike placed at the Chicago International Motorcycle Show a couple of years ago... I did the paint on it... )

(https://scontent.ford1-1.fna.fbcdn.net/v/t1.0-9/10422975_10203946677936279_5059197387683439412_n.jpg?oh=68a269b9768553a609ed4c47ee550946&oe=5B187838)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on Feb 13, 2018, 07:11:28
If you guys keep talking like this, I'm going to end up with an HD. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: WhyNot on Feb 13, 2018, 07:17:14
I have this:

Just can't do much else to it.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 13, 2018, 11:04:12
I have this:

Just can't do much else to it.
http://billetcharger.com/?page_id=38
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Feb 13, 2018, 11:45:11
http://billetcharger.com/?page_id=38

Lol, excellent response.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 13, 2018, 11:50:14
Lol, excellent response.

There's always more to do... it's just a matter of money, time and desire....

As soon as my 2017 Road Glide's Milwaukee 8 is out of warranty next spring I'm taking it up to Fuel Moto for the 120" treatment... they are getting outstanding numbers out of their kit.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on Feb 13, 2018, 11:54:01
If you guys keep talking like this, I'm going to end up with an HD.

Potato potato potato
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Sonreir on Feb 13, 2018, 12:03:54
If you guys keep talking like this, I'm going to end up with an HD. 

Right?
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Feb 13, 2018, 18:39:59
I've got a buddy with a Hammer 1250 top end... he had them do his heads and everything. I think the "Smash" service.. and he's busting a a solid 110+hp... that bike is a beast of a sporty and Hammer is getting even more with the 1275 jugs. (That bike placed at the Chicago International Motorcycle Show a couple of years ago... I did the paint on it... )

(https://scontent.ford1-1.fna.fbcdn.net/v/t1.0-9/10422975_10203946677936279_5059197387683439412_n.jpg?oh=68a269b9768553a609ed4c47ee550946&oe=5B187838)


Wow, probably has a ton of torque too!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Feb 22, 2018, 15:27:20
Decision made.. with as good as my bores are and as good as the bike performed before the tear down... I'm just going to leave the pistons and bores alone the bike had plenty of power and the new intake/jetting/exhaust/cams and a proper tune should make it a really good runner. A big bore kit is just a couple of hours worth of work if I decide to do it in the future.

Now if I can just get my engine covers back from my powder coater.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Mar 24, 2018, 13:53:46
So I finally was able to pickup my engine covers from the Powder Coater yesterday. Now that I'm back on track... i'll work on getting the motor back together, exhaust mounted and onto the body work.

(https://farm5.staticflickr.com/4777/40096641505_a68e6ecbb9_b.jpg) (https://flic.kr/p/246cLzg)
(https://farm1.staticflickr.com/821/40948106972_b10f32b50c_b.jpg) (https://flic.kr/p/25orKAm)
(https://farm1.staticflickr.com/808/40096641495_94f22e2dc9_b.jpg) (https://flic.kr/p/246cLz6)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on Mar 24, 2018, 14:20:54
Gorgeous color bud.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on Mar 24, 2018, 14:21:38
Hey don't forget to vote for Rachels 400 BOTM.   :)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Mar 24, 2018, 16:27:28
Hey don't forget to vote for Rachels 400 BOTM.   :)
Done
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: killerx on Mar 28, 2018, 13:28:44
Those cases look awesome!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Mar 31, 2018, 20:33:01
I got out and started getting the motor back together today...
Here I have the heads and push rod tubes installed and torqued down.
(https://farm1.staticflickr.com/805/27271471518_c1a43a6e75_b.jpg) (https://flic.kr/p/HxTqmN)

Rocker boxes installed
(https://farm1.staticflickr.com/805/39335933550_2ab7953d02_b.jpg) (https://flic.kr/p/22VYWAS)

Rocker box covers installed.
(https://farm1.staticflickr.com/808/39335933610_b75ca31c86_b.jpg) (https://flic.kr/p/22VYWBU)

Next up I'll get the covers on tomorrow... now off to the movies with a hot blonde.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Apr 01, 2018, 16:58:58
Got the right side mostly together today. Getting excited... now onto the left side and then the exhaust.
(https://farm1.staticflickr.com/805/40452517984_45a82de345_b.jpg) (https://flic.kr/p/24CDJfC)
(https://farm1.staticflickr.com/875/39356012450_69d17bb0f9_b.jpg) (https://flic.kr/p/22XKRmN)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on Apr 01, 2018, 17:05:10
I'm learning about these bikes while I work on my first one.  How do you deal with the crankcase breather since you're not using the hollow bolts to mount your air cleaner bracket?  I just forked out $45 for two of those bolts, but I'm curious if there was an option I missed.  Forums talk about rocker box breathers, but I'm not sure I have that option.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Apr 01, 2018, 17:39:20
I'm learning about these bikes while I work on my first one.  How do you deal with the crankcase breather since you're not using the hollow bolts to mount your air cleaner bracket?  I just forked out $45 for two of those bolts, but I'm curious if there was an option I missed.  Forums talk about rocker box breathers, but I'm not sure I have that option.

The bolts are gun drilled and vented below the head and there's a pathway into the carb inlet... so it's as you'd expect, it's just hidden well.

You can see in this diagram how it's put together... (these intakes are CHEAP and built really well.)

(https://i.ebayimg.com/images/g/ngYAAOSw~M1Zlv2Z/s-l1600.jpg)

You need a lathe, best investment I ever made. paid for itself many times over.... I'd drilled off the shelf bolts myself before forking out moolah like that on specialty bolts. Sportster parts are all over ebay and aftermarket... post wanted ads on HDforums and even CL or Facebook market place... not hard to find what you need.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on Apr 01, 2018, 18:32:19
I have a lathe, but for some reason I bought the bolts off the shelf.  I wasn't sure if there was something I was missing in how it all worked. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Apr 03, 2018, 20:55:39
I needed a spare set of hands to install the exhaust, so my buddy George came over today and helped me out. I might need to add some spacers to move the exhaust tip out a little but I won't know for sure until I get the weight back down on the rear wheel... anyway here's how it looks with the pipes.

(https://farm1.staticflickr.com/885/27345723618_ca8f409df8_b.jpg) (https://flic.kr/p/HErYVq)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Apr 04, 2018, 12:32:50
Continues to look great, love the exhaust.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: JustinLonghorn on Apr 04, 2018, 12:51:08
Rad. I am on board.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Apr 08, 2018, 18:57:43
Got the primary side put back together today... I think I'll need to shorten the clutch cable a couple of inches... it's okay but could be a smidgen tidier. So far this bike has been an absolute pleasure to work on mechanically speaking.

(https://farm1.staticflickr.com/876/40431669295_8bdb794a3e_b.jpg) (https://flic.kr/p/24ANSEt)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Apr 08, 2018, 20:54:34
Looks so sanitary, fantastic!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Apr 18, 2018, 22:53:04
I did a swap of the original chrome kickstand for a 1" longer black one to keep the thing from leaning over too far with the extra lift from the longer shocks. I did pick my paint color and have it on order. I am going with a Jeep Sunburst Orange... I'll probably work in a graphic of some kind, I'll think about it while I'm drunk in Mexico next week. Hopefully the weather will warm up enough for me to paint soon... that's all that is left besides some final assembly and tail light wiring.

(https://farm1.staticflickr.com/937/40657077095_3852f81475_b.jpg) (https://flic.kr/p/24WJ9xR)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 02, 2018, 22:31:38
Now I'm finally onto the pretty bits and onto prepping for paint... I had a few extra holes in the rear fender to weld up so I knocked that out tonight.
(https://farm1.staticflickr.com/946/26989661007_048e2d7d00_b.jpg) (https://flic.kr/p/H7Z4UT)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 07, 2018, 11:29:43
I managed to get all the body work done and get the thin into primer. I'm going to give everything a final sanding and get a sealer coat on things this week with the anticipation of getting some color laid down this coming weekend. I'll probably paint it in two sessions, fenders then tank and side covers... or maybe just the tank separately form everything else.

(https://farm1.staticflickr.com/973/41951792071_265c702500_b.jpg) (https://flic.kr/p/26V8UcR)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Maritime on May 07, 2018, 11:56:33
Wow, how have I not seen this before now. Can;t wait to see the paint work!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 07, 2018, 13:33:50
Your bike is looking fantastic!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 11, 2018, 15:44:16
The weather today is perfect for me to paint outside... (the only option I have unfortunately.) So I took the day off work and built some painting fixtures from some cheap Harbor Frieght work tables ($14 each for Insiders ;)) I just laid down the first round of clear coat. I'll do at least 2 more clear coat sessions on it and that'll be more than plenty to be able to cut and buff out the finish to look amazing. I think this burnt orange color is going to fit with the powder coat colors nicely.

(https://farm1.staticflickr.com/947/41323089614_ffccabd59f_b.jpg) (https://flic.kr/p/25XzCSj)
(https://farm1.staticflickr.com/946/41323089934_2d0a9bb5b1_b.jpg) (https://flic.kr/p/25XzCXQ)
(https://farm1.staticflickr.com/903/41323090634_edcd14c94c_b.jpg) (https://flic.kr/p/25XzDaU)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Maritime on May 11, 2018, 16:04:41
Beauty, and I have to do the same painting outside. Still not able to here yet LOL.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: The Jimbonaut on May 11, 2018, 16:11:22
That colour is gorgeous man, great job
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: irk miller on May 11, 2018, 17:12:35
Really is nice.  Growing up, my old man painted all of his cars in the back yard.  These were some pretty sweet hotrods, too.  He's always made me feel okay about it. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 11, 2018, 19:13:50
Thank guys... I'm gonna do some matte black vinyl decaling on it to kinda re-enforce the tactical look... I've got a couple of other goodies cooking too that I've yet to reveal. I've got to place a couple of orders to see if it's going to work... my short ass rear fender might not work with my idea. But i'm gonna have to spend money to see. (Which annoys me)

BUT I should be able to get the tins buffed out and reinstalled and the tail-light wiring and tank plumbing done by next weekend. If I don't dick around I might even be able to get the thing started and ride-able.

 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 12, 2018, 02:32:41
That paint is sweet.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: WhyNot on May 12, 2018, 06:27:37
That's burnt orange, from what manufacturer?

I'm planning on painting mine burnt orange, just wondering if the color I have is the same.

Looks sweet.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 13, 2018, 23:11:19
That's burnt orange, from what manufacturer?

I'm planning on painting mine burnt orange, just wondering if the color I have is the same.

Looks sweet.
It's Chrysler PV6 (Sunburst Orange)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 13, 2018, 23:15:29
I'm in the buffing stage now. I have the fenders and side covers done. I'll work on the tank tomorrow night but here's a little preview.

(https://farm1.staticflickr.com/976/41192748345_8fe5c75349_b.jpg) (https://flic.kr/p/25L4AX4)
(https://farm1.staticflickr.com/966/41192748275_a8eacb5d21_b.jpg) (https://flic.kr/p/25L4AVR)
(https://farm1.staticflickr.com/830/41193878465_49fc969896_b.jpg) (https://flic.kr/p/25LaoTT)
Gotcha ;)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on May 14, 2018, 08:26:47
Wow bud, looking spectacular.   8)

What are you using for buffing?
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: WhyNot on May 14, 2018, 08:30:41
wow that is nice...............!!!!!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 14, 2018, 11:19:29
Wow bud, looking spectacular.   8)

What are you using for buffing?
Wet sanding with a flexible block from 800 through 2000 grit wet/dry and polishing on a 14Ē pedestal buffer with Menzerna dry compounds.




Sent from my iPhone using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 14, 2018, 13:10:35
Wow bud, looking spectacular.   8)

What are you using for buffing?

I agree!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 15, 2018, 09:03:32
I made some custom flat black decals last night to start tying the paint and powder together. I got the underside of the fenders done up with some undercoating and the wiring started on the rear fender... I'll get that squared away tonight and get started on the tank Wed.

(https://farm1.staticflickr.com/943/28253611158_bd2ca1ace2_b.jpg) (https://flic.kr/p/K3F9fS)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Maritime on May 15, 2018, 09:13:07
This thing is all kinds of rad!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on May 15, 2018, 13:22:54
I'm in the buffing stage now. I have the fenders and side covers done. I'll work on the tank tomorrow night but here's a little preview.

(https://farm1.staticflickr.com/976/41192748345_8fe5c75349_b.jpg) (https://flic.kr/p/25L4AX4)
(https://farm1.staticflickr.com/966/41192748275_a8eacb5d21_b.jpg) (https://flic.kr/p/25L4AVR)
(https://farm1.staticflickr.com/830/41193878465_49fc969896_b.jpg) (https://flic.kr/p/25LaoTT)
Gotcha ;)
Ha...sure did and made me laugh.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 16, 2018, 12:16:33
Quick update. I've got the tins all polished out and decals installed. Tail light is wired, petcock and choke are hooked up. Just need to clean the garage, make sure the chain is tensioned and run down a check for loose bolts/nuts. Then I can put some fuel in it and turn it over.
(https://farm1.staticflickr.com/945/27279981507_54a4b53701_b.jpg) (https://flic.kr/p/HyD35K)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: trek97 on May 16, 2018, 15:51:30
I do dig that exhaust setup.    8)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 1fasgsxr on May 16, 2018, 21:03:30
I bet it will sound great. I don't like the typical "drag pipes" sound
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 17, 2018, 11:39:02
I did a little garage clean up last night and got the bike off the lift... The bike leans over way too far on the side stand even with the 1" extended stand. I'm going to have to lengthen and modify the stop on the stand to make the side stand right. 

(https://farm1.staticflickr.com/964/40363523040_f00a7a7125_b.jpg) (https://flic.kr/p/24uMBa3)
(https://farm1.staticflickr.com/977/42170454331_436ed68ea0_b.jpg) (https://flic.kr/p/27fsASP)
(https://farm1.staticflickr.com/823/42124269212_49eea5109a_b.jpg) (https://flic.kr/p/27bnTDE)

And a copy of my remaining punch list items.
(https://farm1.staticflickr.com/961/42170454151_5da5ef15b9_b.jpg) (https://flic.kr/p/27fsAPH)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 17, 2018, 23:09:51
Oh man, your bike looks so pristine and crisp and so sexy, well done sir!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 17, 2018, 23:48:03
Thanks for the compliments guys. I did a little more decal work on it tonight... I think this looks a little more bad ass and rugged. I've not decided if I need a stripe on the front fender.

(https://farm1.staticflickr.com/980/41461193154_dbd41c880a_b.jpg) (https://flic.kr/p/26aMseQ)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: SONIC. on May 18, 2018, 10:37:50
Loving it man.

My only thought is can the headlight move up an inch or so? It's below the line of the bottom and the tank and it draws my eye. I moved it up an inch or so in photoshop just to see if I liked it. I'ts attached.

That thing looks like a blast!

(https://farm1.staticflickr.com/964/40363523040_f00a7a7125_b.jpg)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 18, 2018, 10:51:13
Loving it man.

My only thought is can the headlight move up an inch or so? It's below the line of the bottom and the tank and it draws my eye. I moved it up an inch or so in photoshop just to see if I liked it. I'ts attached.

That thing looks like a blast!

(https://farm1.staticflickr.com/964/40363523040_f00a7a7125_b.jpg)

Good eye!!! It is something I am addressing as it bugs my eye too. I actually have another headlight mount fabricated to do just that I just havenít powder coated it yet.

When I modify the kick stand I plan to powder it and install it.


Sent from my iPhone using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: SONIC. on May 18, 2018, 11:55:39

Good eye!!! It is something I am addressing as it bugs my eye too. I actually have another headlight mount fabricated to do just that I just havenít powder coated it yet.

When I modify the kick stand I plan to powder it and install it.


Sent from my iPhone using Tapatalk

My man!
That's what I'm talking about.
Gonna be a badass bike man!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 18, 2018, 11:55:58
I went ahead and made up some stripes for the front fender and installed them... I think I approve... I also wrapped the exposed bit of fork tube between the triple trees with the same matte black vinyl... I like that. I took the day off from work today to get some real progress made on this thing today, I have already marked a couple of things off the punch list... we'll see if I can get a few more items marked off and maybe toss some gas in this thing today.

(https://farm1.staticflickr.com/948/40384536750_ca28cc9c9e_b.jpg) (https://flic.kr/p/24wDiNo)
Title: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 18, 2018, 19:16:56
So I got my punch list all done and put a bit of gas in the tank and sure as shit it fired right up. (the smoke is the new exhaust heating up the first time.)
https://youtu.be/vKkn6pqoniU

I gave it a ride down to the gas station and topped off the tank.... MAN the new cams/intake/carb kit/exhaust really woke this girl up... the carb even performs good with the recommended starting point of 1-1/4 turns out on the mix screw... I'll get around a little on it tomorrow but I'm really pleased with the riding position and handling.

Here's a pic of it outside the garage.
(https://farm1.staticflickr.com/949/42151989412_fdd0f64962_b.jpg) (https://flic.kr/p/27dPXU9)

Don't forget here's what I started with
(https://farm5.staticflickr.com/4490/23704316198_c92a178b79_k.jpg) (https://flic.kr/p/C7EPmS)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: doc_rot on May 18, 2018, 19:56:15
Looks fantastic man. the burnt orange compliments the bronze really well
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 19, 2018, 04:16:11
It must be lighter than originally, do you have an idea of how much?  By the way, I still love this bike.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 19, 2018, 13:10:19
It must be lighter than originally, do you have an idea of how much?  By the way, I still love this bike.

Yeah the wheel swap alone was a huge weight savings I bet I shed near 50 lbs or more between that and the screaming eagle exhaust those things weighed so much compared to the replacements. The new tank, tail and bar/cluster, seat all weigh considerably less too... Iíd guess I shed 60# total...

Gonna ride it out to get a haircut in a bit and try to get some good pics.


Sent from my iPhone using Tapatalk
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: JustinLonghorn on May 19, 2018, 14:40:24
I really do enjoy this scoot, man!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 20, 2018, 21:33:36
I really do enjoy this scoot, man!

Thanks.. it's not quite 100% done yet... I really want to add a skid plate, front fender extension and a set of SW Motech SLC carriers, a left side bag, and a pair of Dry-Spec tubes on the right side for a fuel bottle and tool-kit (or two fuel bottles). the Sportster carriers are out of stock, I've got an email in to Twisted Throttle to get a lead time on refreshed stock. This bike will be a legit dual sport bike with some ability to carry some cargo and stuff.

Need to do a little carb tuning, I'm running a 46 pilot jet and I'm getting no adjustment on the mix screw. It runs well enough as is, but I'd rather bump it to a 48 pilot and get some adjust-ability in there. I have new pilots on the way...

(I'm also always flipping back-and-forth on do I spend bike funds on the sporty or the Road Glide)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 24, 2018, 00:16:23
I knocked out quick skid plate out of some aluminum diamond plate after work today. I may or may not powder it... not decided.

(https://farm1.staticflickr.com/971/40507117780_78451439c0_b.jpg) (https://flic.kr/p/24HtySq)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on May 24, 2018, 15:35:12
My .02.  Do the powder, same color as the heads.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: JustinLonghorn on May 24, 2018, 15:45:38
(https://vignette.wikia.nocookie.net/cardfight/images/9/92/He%27s_right_you_know.jpg/revision/latest?cb=20151003212955)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 24, 2018, 18:35:04
My .02.  Do the powder, same color as the heads.

The heads are black with edge cut fins....

Do you mean Charcoal like the the rocker boxes? or Bronze like the Rocker Box covers? (The rocker box is separate from the head on an Evo motor.)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Brodie on May 24, 2018, 19:18:12
My vote is for bronze.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 24, 2018, 21:20:52
Matching the heads would look good but I wonder about the plate getting hit with a lot of rocks and other crap that could scratch it up. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on May 24, 2018, 23:14:04
Matching the heads would look good but I wonder about the plate getting hit with a lot of rocks and other crap that could scratch it up.

That's my thinking for not doing the powder right away... most skid plates are raw aluminum. A few are available in black powder but most are raw.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: canyoncarver on May 29, 2018, 14:15:02
The heads are black with edge cut fins....

Do you mean Charcoal like the the rocker boxes? or Bronze like the Rocker Box covers? (The rocker box is separate from the head on an Evo motor.)

Sorry, yes I meant the same color as the rocker box covers.  The rocker box covers are separate on pretty much all HD's. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: SONIC. on May 31, 2018, 10:04:06
I say powder it. Bronze.
The shiny aluminum just doesn't do it for me, seems out of place.

Yes the powder will get scratched and chipped, but if it's truly a dual sport who cares? Par for the course!

Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: The Jimbonaut on May 31, 2018, 10:17:06
Another vote for bronze.  I was talking to my neighbour the other day who was pulling up in his freshly minted Audi - he'd just dropped a few hundred bucks on clear vinyl wrapping his hood.  After a year or so or getting hammered by stone chips etc you just peel off the vinyl that's taken a few for the team and replace it - the paint underneath is undamaged.

Wonder of you could powder the plate, and then wrap it.  The wrap'll get the crap kicked out of it but it'll protect the paint - replace the vinyl as/when needed. 
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: Maritime on May 31, 2018, 11:03:36
That stuff is great on new paint/powder. FIL had it done on a Passat and it protected the hood great. Can't see why not on a bash plate.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on May 31, 2018, 20:58:00
Bronze would look good, for sure.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jun 01, 2018, 08:58:46
Agh you guys are killing me... I've got to pull the carb and manifold sometime this weekend to replace the manifold to head seals and dig around the pilot / air mix screw circuit to figure out why the mix screw is ineffective. I went to a 48 pilot and still no adjustment... Stock is a 45, most Stage 1 / 2 setups only need a 46 pilot. I thought I had all circuits clean when I did the rebuild.  (This was a symptom the bike exhibited before I tore it down and is what prompted me to rebuild the carb.)

But I'll probably pull the skid plate and powder it while I'm wrenching on it.
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jun 03, 2018, 22:58:07
Okay, So I powdered up the skid plate in bronze. I got out and rode about 100 miles today on it... it's running pretty okay, I still have some carb tweaking to do... it's running pretty okay, I am running a CVP needle / emulsion tube and Main jet... as a system I don't know that everything together is really spot on. I'm going to go back to the stock needle, emulsion tube and a 185 or 180 main jet and see where I am... I think I made too many changes at once to know what's up. It pulls really hard now when i get into mid throttle and get the RPM up... it's a little flat transitioning from pilot to main though. But even then it was still a pleasure to ride today for a decent ride.

(https://farm2.staticflickr.com/1755/40740437880_ebd02c9514_b.jpg) (https://flic.kr/p/2556oNL)
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: 3DogNate on Jun 03, 2018, 23:04:51
Here are some better pictures of it that I grabbed last week. The skid plate is still raw aluminum, and I've since flipped the mirrors to the bottom side of the bars for visibility as the wide bars it's difficult to see behind me past my arms and shoulders. I've gotten really good feedback from everyone that has seen it in person, very pleased.

(https://farm2.staticflickr.com/1757/40740448900_b07c58e3ed_b.jpg) (https://flic.kr/p/2556s5L)
(https://farm2.staticflickr.com/1751/41646966845_2e1df11533_b.jpg) (https://flic.kr/p/26scAhv)
(https://farm2.staticflickr.com/1728/42549016971_f1579af135_b.jpg) (https://flic.kr/p/27PUQmT)
(https://farm2.staticflickr.com/1740/40740459600_ebe8e039a3_b.jpg) (https://flic.kr/p/2556vgf)


Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: CrabsAndCylinders on Jun 04, 2018, 17:14:20
Sweet!
Title: Re: 3DogNate's '05 H-D Sportster Scrambler build - AKA "Project Dual-Sportster"
Post by: The Jimbonaut on Jun 04, 2018, 17:35:03
Really great looking sportster man, beautifully done.  The bronze elements are pure class.  Every time I see a decent looking sporty I'm bummed I sold mine!