DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Bevelheadmhr on Oct 16, 2013, 15:55:25

Title: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 15:55:25
Hi all,

Been lurking on here for long enough, so thought I'd start a build thread on my café project. I was half way through another project (a Guzzi café) and started to think about what to do the next. By chance I got talking to a chap who was selling a chopped Ironhead XL1000 Harley for the widow of a friend who'd died awhile ago, since when the bike had stood unused. It was cheap and came with a rebuilt engine and a £3000 of receipts for the work. I went to see it and bought it.

I then got a tour of the small workshop where the chap repaired old frames and made new replicas of Norton frames. I was impressed with their work, and once the bike was home, I decided to order one of their frames, which had to be made for me as the old Ironhead motors have slightly different mounts to the modern Evo Sportsters. I also ordered an oil tank and slim line petrol tank.

A few weeks passed while I waited for my frame, in the meantime I stripped the old Ironhead down and did a little tidying up on the engine cases..

The only thing I'll keep from the doner bike is the engine..

Polishing the primary cover by hand.. takes a long time..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 16:00:41
Here's a couple of photos I took at the Norley workshop when I went to view the Harley..

Buell based Norley..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 16:05:15
A good day.. my frame arrives  :)

I'm building this on a very small budget, so its going to take awhile, as I want it just right with no short cuts. All I could do for now was to fit a pair of YSS shocks which had been built to my spec at a very good price, cheaper than Hagons..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 16:08:46
Time to see if the engine fits the frame.. Needed an extra pair of hands, those Ironheads are bloody heavy, but it went in ok without too much swearing..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: coyote13 on Oct 16, 2013, 16:20:56
You have my undivided attention.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 17:15:40
Since I had to wait while I saved my pennies for the cool parts I wanted, I got busy doing the tedious work cleaning up the engine..First the generator, took it apart, cleaned, checked and painted, ditto the starter motor, had a peak inside, looks ok thankfully, so just cleaned and painted it..
 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 18:20:39
Finally I could buy a few engine parts.. new push rod tubes, full gasket set, some electrical parts, including a rectifier which replaces the genny end cover and cleans up the wiring.. and an S&S Super E carb..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead13013_zps5473325e.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead13013_zps5473325e.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead13015_zps0abdf498.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead13015_zps0abdf498.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead14001.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead14001.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 18:33:22
The new carb didn't come with an air filter, as I didn't want to fit the classic S&S teardrop cover. I had a velocity stack left over from an old project, so that went on. Probably wont end up using it, but it will do until I can find or make something better..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead14012.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead14012.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Anthiron on Oct 16, 2013, 18:43:49
Definitely watching this one!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 19:02:20
I'm condensing about a year in a few minutes on here, I'm up to last summer now, and time to sort out a front end. I sometimes help out at my local bikeshop, which means I can sometimes get a bargain. When I was offered a mint set of forks from a Honda Hornet 900, I couldn't say no, especially as they were free  :)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead15005.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead15005.jpg.html)

They didn't come with yokes, and even if they did, it wouldn't fit the Norley frame, which is made to take HD head bearings. At this point I went to see my mate Jeff, he makes one off parts from his small home workshop. He owed me a favour so I came home with a couple of half finished billet yokes Jeff had made in the past, both were drilled to take 43mm forks, same as the Hondas... I wanted something a bit retro in keeping with the café style, so picked the best one..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead15004.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead15004.jpg.html)   

Next we pressed out a stem from an old pair of yokes I had, and Jeff machined the yokes to take the HD stem..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead17002.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead17002.jpg.html)

I bought a pair of cheap clip ons, which didn't look too bad ...
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead30004.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead30004.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 16, 2013, 19:52:46
I can't wait for the next installment!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 20:32:43
You don't have to wait too long  :)

About ten years ago I was given a box of spares from a Yam XJR turbo streetfighter (a long story), it had been sitting on a shelf all this time, until I remembered it during a tidying up. Most of the contents were useless, except for a mismatched pair of rearsets by the German company LSL. Wonder if I could use these I thought? Expecting to have to make new mounts, I tried them out. Amazingly they almost fit straight on, only a couple of mm out, which wouldn't be a problem. I would have to make a suitable master cylinder mount and pushrod and a linkage for the gearchange.. But first I had to remove the anodising from the levers as they were different colours..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 20:37:24
Time for a chemistry experiment.. using caustic soda in solution to remove the anodising...

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets4001.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets4001.jpg.html)

something is happening, lots of bubbles and fizzing..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets4004.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets4004.jpg.html)

After ten minutes..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets4008.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets4008.jpg.html)

Then just had to polish them and they look ok..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Rearsets5002.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Rearsets5002.jpg.html)

The one problem now is that the rearsets are really far back, about where you'd expect to find pillion pegs,but I reckon I can live with them.. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 20:47:40
Now I had to make a gear change linkage using parts from the original bikes highway pegs and my new rearsets..

This is my MK1 version, if it works ok in use I can always make a better looking MK2..

Step 1.. Turned the old splined lever upside down, cut the end off and file a flat on its side..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Rearsets5001-1.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Rearsets5001-1.jpg.html)

Step 2.. Make a simple triangle and bolt it to the side of the lever, and use it to mount a rose joint,which in turn will be one end of a shift rod. I used a bent wire to give me an idea for the shape of the new shift rod..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Rearsets6005.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Rearsets6005.jpg.html)

Step 3.. tap a thread in each end of a stainless bar, then heat and bend it into shape..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets7001.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets7001.jpg.html)

Its not very pretty, but it seems to work ok, and so far had cost only a few pounds for the stainless rose joint and clevis joint used on the ends of the shift rod. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 16, 2013, 20:57:51
Turning to the rear brake, this was a bit more involved. I had a second hand Brembo master cylinder, from a Ducati monster, which I made a simple mounting bracket for using a scrap piece of alloy plate...

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets7003.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets7003.jpg.html)

Tapping a thread into the bracket before I file it into its final shape..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets9001.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets9001.jpg.html)

I didn't have a pushrod for the master cylinder, so Jeff kindly machined one up from a stainless bolt while I had break and nice cup of tea ..all my projects are sustained by tea  :)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets9002.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets9002.jpg.html)

All done, again I used stainless rose joint in the linkage...
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/rearsets9007.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/rearsets9007.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckfever5 on Oct 16, 2013, 22:25:53
I'll be watching this one.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 02:46:46
I bought these neat Daytona clocks, they look retro in their stainless cases, but are pretty high tech, can show peak revs, temp, even a clock..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/clocks1004.jpg)

I then made new mounts for them, as the stainless ones they came with the clocks didn't look right to me. I made a cock up when drilling the mounting holes in the underside of the top yoke, I was so intent on making sure I didn't drill all the way through the yoke, that I mistakenly used an 8mm drill bit for the M8 sized holes.. that's too big to allow a thread to be cut using a M8 tap. So as usual when I mess up I went over to see my mate Jeff with my sorry tale and while I drank tea he kindly drilled the holes out a bit more and used helicoil thread inserts to get back to an M8. Well, since I was there, we made a couple of stainless pieces for the steering lock and drilled the lower yoke where I guessed they should go. Cant say for sure, as the frame doesn't have a tab on the headstock, its one of those things I'll have to sort out later. We made them a bit longer than they probably will need to be, that way they can be machined down a bit if needed, once everything is together on the bike.


I made the new brackets from an offcut of alloy plate, using the original to trace out the shape and drill the three holes in each. Then it was a case of hacksawing out the shape and spending a long time with a file and wet and dry to get a reasonable finish. Still need to pretty it up, but it looks ok so far. I've still to make the idiot light bracket, which is a bit more complex, so far I've drilled all the holes and cut out the shape I need roughly with the hacksaw. Wish I had use of Jeffs miller, it would be much quicker and neater, but it was in use all that week, making a blower manifold for our drag bike.. Later I changed the way the clocks were mounted to tuck them in closer to the top yoke. 

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Yolks2032.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Clocks3002.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/yokes5005.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/yokes5007.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 02:48:55
The next job was to  make a new head steady, as I wasn't happy with the original, though I'm sure it would've done the job ok, I decided to make one in alloy which would be lighter and stronger, and shinier ..


I marked out the shape on a scrap piece of aircraft spec alloy, then chain drilled out. I would've taken me ages to file the sides to a respectable finish, but luckily Jeff took pity on me and did the job in five minutes on the miller. Which left me to just finish the corners with a file and drill those all important lightening holes.. surprising it fit ok on the bike.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead40011.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead40015.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/ironhead42010.jpg)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Yokes7002.jpg)

A pair of chromed alloy wheel hubs arrived soon after, a xmas pressie from me to me.. They are set up with 3/4 inch bearings, while the Honda forks have a 20mm spindle. I was intending to machine the Honda spindle down and make a top hat for one end so it still fits the forks. But the spindle is hollow, and it wouldn't be a good idea to machine it down anymore. So instead, we'll use an old Harley spindle and make it fit the fork legs, its solid and probably made out of pig iron lol. One problem I may have is that the front calipers may hit the spokes once the wheel is laced. Not sure yet, but it'll close either way.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/ironhead41004.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 02:52:01
The HD front hub has been causing a headache, I couldn't find any bearings that would fit the hub and work with the Honda 20mm spindle. Nor could I just machine down the spindle to 3/4 of an inch, as it was hollow and I didn't want to weaken it too much. Somehow I had to modify the original HD wheel spindle to fit the Honda forks..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/ironhead41006.jpg)

Well, there was only one thing to do.. hand the problem over to my mate Jeff and his trusty lathe.. 5 hours of machining later the job was done.. Its this sort of problem that can really delay a project, without help I'd never finish mine that's for sure..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead66005_zps4c8d8587.jpg)


With the forks back on the bike, the next task was to buy a pair of 18 inch Morad alloy rims and stainless spokes and build the wheels, I'd never laced a motorcycle wheel before, so should be interesting
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 02:54:56
A month later I ordered the rims and spokes from Central wheel company in Birmingham which arrived in a couple of days, and also some parts from Unity Equipe.. seat, stainless sidestand and tank strap and catch.


Then I had a go at lacing a wheel for the first time. I made a few silly mistakes along the way, but the rear wheel wasn't as difficult as I'd thought. Though of course I still needed to true it. Full of confidence, I started on the front wheel, expecting to be finished in no time. After three attempts I gave up for the evening. The main problem is that all the holes in the hub for the spokes are all bevelled on one side only, so all the spokes have to be seated on the same side. When the spokes cross it means that one of the spokes doesn't sit in its seat correctly. Obviously I'm lacing it in the wrong way, but I couldn't see the right way at that moment.


Rear wheel..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/May012013008_zps2cde11ca.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/May012013008_zps2cde11ca.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/May012013009_zps29ba472a.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/May012013009_zps29ba472a.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/May012013011_zpsaec52671.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/May012013011_zpsaec52671.jpg.html)


Front wheel.. going ok, then it all went wrong
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/May012013013_zps10a058af.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/May012013013_zps10a058af.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/May012013017_zpsbd9209d0.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/May012013017_zpsbd9209d0.jpg.html)

More later...
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 03:32:27
I didn't get very far with lacing the front wheel, so on the basis that the only stupid question is the one you don't ask, I popped around the corner to see Bill, a chap in his eighties who has been restoring veteran bikes since before I was born. Bill who soon pointed out my beginners error. When I unpacked the spokes, the rear spokes were in two bags. I did check to see if there were any differences but they were the same length and had the same angle of bend. So without further thought I got stuck in. Bill pointed out that I had two different spoke sets, one of which had a slightly longer bend, these should be used when a spoke crosses on top of another at the hub. Mystery solved, he kindly offered to finish the wheel for me and true it up, in the meantime I admired the last of the three 1920s Sunbeams he'd restored, from being piles of rust dug up out of ground of a old scrap yard. Not to mention his Velocette, Vincent Rapide and a couple of specials.. I must remember to take my camera next time I visit.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 03:33:20
I did a quick test fit of the seat from Unity Equipe, the two stubs which mount it to the frame didn't quite match up, but I threatened them with a big hammer and eventually the seat went on. It seems a bit too far back, but not sure yet..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead69005_zps39bd3ab5.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead69005_zps39bd3ab5.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead69007_zpsf4b56111.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead69007_zpsf4b56111.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 03:34:31
With the wheels built at last, I reused the front disc spacers from the original bike on the new hub, with some machining to fit the EBC discs. The rear disc mounting holes also had to be widened (as HD hubs use bigger bolts on the back than the front) and disc manufacturers don't seem to bother drilling the correct size holes. I needed to find a rear Nissin caliper before I could make a caliper mount and wheel spacers for the back wheel.

Here's a blurry vid I just took of progress to date, you can see there's not much room as I'm working in the conversatory, as the garage is full up with my other bikes.
 
http://youtu.be/MeqE9wE2gTY
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 03:35:42
One of the favourite parts I've bought so far is this toggle for the tank strap, lovely bit of kit. The tank strap has to be sized and a hook pop rivetted onto the strap, but need to make the buckle at the other end yet.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead71005_zps51832202.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead71005_zps51832202.jpg.html)


Its almost on its wheels by now, just waiting on the tyres (Avon AM26s). The rear is a 120x18, when I started out on bikes that seemed a huge tyre, now it looks like it belongs on a moped :)


My mad plan for a one off hydraulic clutch conversion are starting to come together, as I swapped an old roll of roofing felt for a mint Brembo clutch slave cylinder :)

..and here it is, a good swap for some old roofing felt I didn't need.. just got to work out a neat way of bolting to the case and extending the clutch pushrod.. sounds easy.. it wasn't ! As you'll see....

 (http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead72005_zpsa4cfe3cb.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead72005_zpsa4cfe3cb.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead72006_zpsc1df3754.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead72006_zpsc1df3754.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Oct 17, 2013, 03:49:58
Nice work mister!!
I`m deeply inlove with them featherbed frames!
Such a shame they are way 2 expensive to build from scratch.(In Norway)
I am planning to put a BMW gs 800 engine in one,but i have to save some money when the Norwegian goverment wants at least 10.000 usd in taxes for a new build  :'(.
But i am on it in a year or soo i hope!
Keep up the good work mister.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 04:20:08
Thanks, is that 10,000 usd just for a frame?? !! Mine came from Norley, cost approx. £1500, with the petrol and oil tanks, came to a total of £2200. Its a really nice frame, very light, made from T45 tubing .. an updated version of the classic Reynolds 531 tubeset.

Here's a little video I took when I visited their workshop for the first time...  I like the way they have a Vincent engine just lying about on the floor..

http://youtu.be/NVT_yPK_4Pg
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Oct 17, 2013, 06:03:09
No its just fee to the goverment to have a licence on it, i have the frame and the engine laying in my fathers workshop,i can build it and use it as a trackbike without anymore costs,but i want it streetlegal and thats bloody expensive for sure. And i have to register as a new (2013)bike  :'( :'(
Nice vid.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Oct 17, 2013, 10:53:26
oh man, I love me some Ironheads.  I was sorely tempted to go this route with my 900, but went chopper instead.  Next time...
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 17, 2013, 12:59:01
 
... i have to save some money when the Norwegian goverment wants at least 10.000 usd in taxes for a new build  :'( .

No its just fee to the goverment to have a licence on it,

You mean it costs 59,338.28 NOK to title a bike with a built from scratch frame?!?  ???
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: RustyOlive on Oct 17, 2013, 14:49:08
Wow! Stunning build!
Following for sure.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc 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.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: bradj on Oct 17, 2013, 15:44:04
Kool project, marc you taking notes
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 16:09:31
Kool project, marc you taking notes
Why would I need to take notes?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: bradj on Oct 17, 2013, 16:50:47
Becouse his parts are all researched and will work together. You just bought stuff to brag about.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr 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
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: WeberKid on Oct 17, 2013, 17:06:00
awesome project!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr 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.
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead73006_zps7f07c932.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead73006_zps7f07c932.jpg.html)

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..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead73001_zpscf9e2d53.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead73001_zpscf9e2d53.jpg.html)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead73002_zps854b94ed.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead73002_zps854b94ed.jpg.html)[/quote]
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr 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
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead77009_zpsc5e7bb7f.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead77009_zpsc5e7bb7f.jpg.html)
Or LOW
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead77004_zps43c03ad4.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead77004_zps43c03ad4.jpg.html)
 
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..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead79001_zps3d682e09.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead79001_zps3d682e09.jpg.html)
 
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..
 
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead78001_zps60da8cc3.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead78001_zps60da8cc3.jpg.html)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead78002_zps6896239e.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead78002_zps6896239e.jpg.html)
 
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.
 
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead79003_zps2492691a.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead79003_zps2492691a.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 17:11:12
Do you have a more intensive build thread elsewhere?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr 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.
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead82001_zps080b3af5.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead82001_zps080b3af5.jpg.html)
 
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..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead83002_zpsa835f545.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead83002_zpsa835f545.jpg.html)
 
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..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead83006_zps837b803d.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead83006_zps837b803d.jpg.html)
The one off slave replaces the clutch inspection cap in the Primary cover(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead83012_zps13fa5493.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead83012_zps13fa5493.jpg.html)

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..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead83004_zps3dc00a98.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead83004_zps3dc00a98.jpg.html)
 
Shiny new caliper.. need to make a mount, torque arm and wheel spacers next..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead83010_zps75cd3be9.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead83010_zps75cd3be9.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 17:17:14
A couple more tasks ticked off the to-do list, first I replaced the generator end cover with an aftermarket one which is also a rectifier. This cleans up the wiring and looks a bit better I think.. 
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead83005_zps99b1e0f5.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead83005_zps99b1e0f5.jpg.html)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead83009_zps08cc19fa.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead83009_zps08cc19fa.jpg.html)

I didn't like the chrome covers that normally get fitted to the end of the generator and starter motor, so with the generator sorted, we made a billet cover for the starter which mimics to style of the new generator cover. Not sure if I'll paint it black with the fins highlighted, or just leave it as is.. (I painted it black and left the fins highlighted in the end)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead84004_zps4d1ad73f.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead84004_zps4d1ad73f.jpg.html)

Just need to make a new mount to sit it a little further over the starter..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead84006_zpsfffe9bad.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead84006_zpsfffe9bad.jpg.html)

All done..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead84005_zps68b70d08.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead84005_zps68b70d08.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 17:23:18
I thought this build looked familiar. It's an old build from another forum I've been following.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 17:28:34
God is in the details.. the wheel spacers are stainless,a bit heavy so we drilled them to lose a few grams. I did try to 'liberate' some of Jeffs precious Titanium to make them, but he wasn't having that  ;D

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead88001_zps13c8d4ab.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead88001_zps13c8d4ab.jpg.html)

Rear caliper bracket done, we needed to machine it down from 20mm plate as it needed to be stepped to give the correct clearance. Well, when I say 'we', I mean that Jeff does the hard work while I drink tea and eat his favourite biscuits and ask lots of questions lol..

URL=http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead88008_zps665c3a04.jpg.html](http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead88008_zps665c3a04.jpg)[/URL]
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 17:37:39
More detail work.. using a hard anodised alloy rear sprocket from Renthal, which was special order for my bike, only took a week to arrive. The sprocket bolts are high grade stainless, which I try to use wherever possible. They looked a bit boring, so we dished the heads on the lathe and saved a few more grams too..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Compbike33009_zps32cfaa6e.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Compbike33009_zps32cfaa6e.jpg.html)

You can see in this photo where I'm up to. The oil tank mount is just temporary, I wont finalise its exact location in the frame until the exhaust is made. Also the rear sprocket is a few mm misaligned with the front sprocket, so the front one will need spacing out a little. The bike looks almost finished, but its probably only about half way completed in terms of man hours so far..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Rolex1001_zpsf34f4a6c.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Rolex1001_zpsf34f4a6c.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 17:42:23
All this far and all in less than a week, wow.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 17:45:32
Headlight and mounts loosely bolted up. Because the yokes are a little wider than standard, had to make a pair of 8mm spacers to mount the shell to the brackets. Its these little jobs that take so long to do (for me at least), mainly because the bike is at home, and any machining is done three miles away at Jeff's place.. at times my measuring isn't as accurate as it needs to be.. though I am slowly getting better.

Another job that took a huge amount of time was the top motor mount, I wanted a billet one to match the head steady that it had to bolt too.. this is the MK3 version.. I also incorporated the ignition key, and left space for a couple more switches.. horn and starter button.. that'll be all the switches the bike is having.. Still needs to be polished yet..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 18:00:42
I thought this build looked familiar. It's an old build from another forum I've been following.

Yes I posted updates on XLF, a good site for HD XL tech info. Its not that old I hope.. its not finished yet !
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 18:04:18
You started the build there over 1 1/2 years ago. It'll take you less than it took me to get as far as we have.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 17, 2013, 18:22:00
I think the pushrod covers shown on the motor are different then the ones you originally bought in the first posts... no?
 
Oh and P.S.
... this shit right here is gonna start making me jack off  :o
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 18:24:58
I think the pushrod covers shown on the motor are different then the ones you originally bought in the first posts... no?
 
Oh and P.S.
... this shit right here is gonna start making me jack off  :o

Good eye, they are the ones that came on it when he bought the bike but if you had read the post it would have been more obvious to you as he shows the new ones and mentions them in a list of items bought.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 17, 2013, 18:34:18
Huh.... wha.... isn't that what I said?.... I'm confused now..... Damn-it Jim Beam after work!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 18:36:04
I guess like most homemade projects, mine progresses as time and money allow. The target is to get it on the road by next spring. I haven't gone into some of the endless details of the build, such as all the options I considered for a seat, or the ratio needed for the master cylinder to work the clutch slave, or which performance cams I'm going to fit and so. Because most folks wouldn't be that interested and I don't have the time to write pages and pages. This thread is more of a summary with lots of photos to show progress, with more details of some of the problems I had to deal with along the way. 18 months isn't that long lol.. my last drag bike took three years, then again are they ever really finished? Once they are on the road, there are always things I want to improve and change.

Actually today I've been to an exhaust specialist and brought back a few metres of 1 3/4 inch stainless tubing and enough bends to make two systems, one for me and one for my mate Tim's XL scrambler..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 18:49:27
I think the pushrod covers shown on the motor are different then the ones you originally bought in the first posts... no?
 
Oh and P.S.
... this shit right here is gonna start making me jack off  :o

The pushrod covers are still the same as when I got the bike, I don't like them and so have bought some new std ones, but haven't fitted them yet. Talking of the motor, it ran fine and had a recent rebuild, but I'll take the heads and barrels off once the dry built is complete and get them powder coated or maybe ceramically coated, not sure yet. It'll also get electronic ignition to replace the points and a set of performance cams, maybe not straight away, but that's the plan. Long term I'd like to make a pair of billet barrels too, but got other projects waiting to do before that..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 17, 2013, 18:53:18
I haven't gone into some of the endless details of the build, such as all the options I considered for a seat, or the ratio needed for the master cylinder to work the clutch slave, or which performance cams I'm going to fit and so. Because most folks wouldn't be that interested

BULLSHIT!
 
...my last drag bike took three years,


The Devil you say... and where pray tell, might I find info on that?  :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 19:29:52
ok, its getting late here in England, so I'll just just leave you with these that I mentioned before..

My old sprint bike.. Merch 120 motor, with NOS.. 424 lbs and 180 bhp... it was fun.. a road bike now..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Merch131120l.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Merch131120l.jpg.html)

racing at Santa Pod
(http://i1122.photobucket.com/albums/l529/Merch131ho/Merch120/IMG_4099.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Merch120/IMG_4099.jpg.html)
(http://i1122.photobucket.com/albums/l529/Merch131ho/Merch120/MF4M0691.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Merch120/MF4M0691.jpg.html)

The current (long term) drag bike project I'm building with my mate Jeff ..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Compbike/ironhead42004.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Compbike/ironhead42004.jpg.html)

And my Guzzi Cali 3 café .. on hold till I finish the Ironhead.. I want to change a lot of the work I've already done on this... just need the time and money  ;)
(http://i1122.photobucket.com/albums/l529/Merch131ho/GuzziProject/Guzzi46012.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/GuzziProject/Guzzi46012.jpg.html)

I have a couple of old Ducatis I've restored too, but they are std.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 17, 2013, 19:30:48
Those that would be interested in the details have already read your tech intensive build thread. Powder coating your heads and cylinders has been discussed as to whether it retains heat. While it does retain some heat it is negligible, while ceramic coatings main intention is to retain heat, my cylinders and heads would be the last place I would use ceramic.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 17, 2013, 19:38:32
Those that would be interested in the details have already read your tech intensive build thread. Powder coating your heads and cylinders has been discussed as to whether it retains heat. While it does retain some heat it is negligible, while ceramic coatings main intention is to retain heat, my cylinders and heads would be the last place I would use ceramic.

That's a good point, I mentioned ceramic coating as I've been thinking about having that treatment on another projects exhaust, and I could get it done for free.. powder coating it is then !
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Oct 18, 2013, 11:33:46
I read an article in The Horse where one of their columnists does a test regarding the heat retention properties of powder coating.  He powder coated one head and painted the other.  then he put them in front of a fan and ran a heat gun through their ports, taking heat measurements as he went.  Then end result was the powder coating held in significantly more heat then the paint did, i do mean significantly. I would never powder any engine parts after reading his article and seeing his numbers.  I used a decent quality spraybomb hi temp heat for my 59 xlh and its held up fine and looks great.

those are some beautiful bikes BTW
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 18, 2013, 11:37:15
Powder coating of cylinders and heads is done quite regularly with no ill effects.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Oct 18, 2013, 11:56:40
Well im not saying your gonna kill the engine by doing it, but its still a bad idea.  These cast iron heads and jugs have a hard enough time trying to dissapate heat as it is, no reason IMO to make it harder.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 18, 2013, 12:01:05
His was one mans test against many hundreds of real world applications that. Whether it retains heat or not is not enough to say never do it. If the powder was applied properly it should be no thicker than paint and therefore should not hold heat any more than paint would. If it won't hurt the motor then there is no reason it is a bad idea.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ILoveThumpers on Oct 18, 2013, 12:24:28
...then end result was the powder coating held in significantly more heat then the paint did, i do mean significantly....

Then they did it wrong. Turbo guys powdercoat intercoolers all the time and there is barely measurable impact.

-Deek
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 18, 2013, 12:28:28
Then they did it wrong. Turbo guys powdercoat intercoolers all the time and there is barely measurable impact.

-Deek

The intercooler manufacturers coat their coolers. As you mentioned the negative results are negligible and almost not measureable.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Oct 18, 2013, 14:51:33
well okay then, do as you will.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 19, 2013, 02:23:00
I haven't decided yet how best to finish the barrels and heads, other than the barrels will be black and the heads a silver/grey colour. I have used engine enamel before which looks ok but was always tricky to get good coverage between the fins etc using a brush... I used this on my Guzzi cafe motor.

So this time if I DIY, I'd like to use some kind of a spray paint. Since the barrels and head are iron, I'm tempted to use smooth Hammerite, which always gives a good tough finish, so long as you follow the instructions to the letter. Also the engine heat will cure Hammerite nicely. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Oct 19, 2013, 03:20:38
beautiful work there !!!
KG formerly kalgard has top shelf engine coatings

http://www.kgcoatings.com/auto-coatings-products.php
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Union Jack on Oct 21, 2013, 14:51:50
WOW!!!!!!!!!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 29, 2013, 15:40:47
Today I've been trying to piece together the downpipes from stainless 13/4 inch tubing, both straight and bends, just taping the pieces for now to work out how its going to look. .. and I got nowhere.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead101001_zpsac08841f.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead101001_zpsac08841f.jpg.html)

The first problem was that I couldn't attach any tubing to the exhaust port, because the 16 gauge tubing was a couple of mm too small to slide onto the engine head. In fact even if I'd used really thin walled 1 3/4 tubing, it still wouldn't have fit.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead101002_zps8c2db32d.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead101002_zps8c2db32d.jpg.html)

Now I have to find away to make it fit.. One option is to expand the end of tube, which I'll look into tomorrow. The other option is to machine a separate (stepped) sleeve which would fit the head and in turn be welded onto the tube. This would take longer to do, but wouldn't cost much.

The second problem I hit was not having the silencers yet. I'd been trying to source a pair of stainless reverse cone megas of the right size for awhile, without success. So today I decided on Plan B.. and I ordered a pair of short chromed megas instead. They'll be here in a few days, they are the size I want, and are made in England with decent quality chrome...I'll make a better looking mount than supplied..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/mortars_3_logo_zps9ee94aa0.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/mortars_3_logo_zps9ee94aa0.jpg.html)

This small change, will have quite a big impact on how the bike will look, as now the downpipes will need to be linished and polished to match the chrome megas.  I had intended to give the bike a raw industrial finish, with the welds left in view, and the
the frame powder coated in clear. But now I think with a polished exhaust the frame will need to be painted too.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 29, 2013, 15:55:00
Too late for you now, and not sure if shipping would be a deal breaker but this is where I go for all things megaphone or exhaust related. Pricing is fair and they have everything or will make it.
 http://www.coneeng.com/exhaust_tips.html
Go to a local muffler shop and they can expand the end of your head pipe or our local auto parts stores have expanders you can borrow (buy it and then return it for refund loaner program). Building a proper exhaust really is an art.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: focusinprogress on Oct 29, 2013, 16:36:09
Love the build! subscribed!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 29, 2013, 16:46:36
Too late for you now, and not sure if shipping would be a deal breaker but this is where I go for all things megaphone or exhaust related. Pricing is fair and they have everything or will make it.
 http://www.coneeng.com/exhaust_tips.html
Go to a local muffler shop and they can expand the end of your head pipe or our local auto parts stores have expanders you can borrow (buy it and then return it for refund loaner program). Building a proper exhaust really is an art.

Yes, I've seen that site before, pity its in the States.. a pair of megas from there are priced at 260 usd, which would be around 400 usd by the time I got them, that's if they ship outside the US, I've found many smaller places wont.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Oct 29, 2013, 17:50:38
Great work Bevelhead - love the featherbeds.  The HD torque will be alot of fun in that chassis.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Oct 29, 2013, 18:06:57
Yes, I've seen that site before, pity its in the States.. a pair of megas from there are priced at 260 usd, which would be around 400 usd by the time I got them, that's if they ship outside the US, I've found many smaller places wont.

You can get the parts you need from them cheaper than some of the already made megs. I am getting a 1-5/8" inlet, 3" outlet, 17" long meg for $25.20. I'll get a 3" Supertrapp end kit for around $30 and have an adjustable meg for my CB400f for around $60.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Oct 29, 2013, 18:24:46
Something like this help? It's a pipe expander available from several sources here in the states... "Lisle" to be a name dropper.
 
(http://www.restockit.com/images/Product/medium/LIS32500.jpg)
 
(http://i.ebayimg.com/t/Small-Tail-Pipe-Expander-Exhaust-Pipes-Muffler-Spreader-/00/s/NzUwWDU2Mw==/z/pUAAAOxyu1FRmMl3/$(KGrHqJHJE0FGW,yIsK9BRmMl3LwPw~~60_35.JPG)
 
(http://ecx.images-amazon.com/images/I/71ailZ-QQbL._SX342_.jpg)
 
(http://www.lislecorp.com/uploads/products/17350inA_8964B2DD0A4A1.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 30, 2013, 10:34:21
There are cheap pipe expander kits on Ebay in the UK, but the reviews suggest they aren't man enough to expand 16 gauge stainless, while the Lisle make is too expensive for me, for something I may never use again. I think I've got a solution which should look neat. TBH the exhaust has been so frustrating, if I could transport the bike easily, I'd take it to a specialist and let them make the headers the way I want. It may come to that, but haven't given up just yet.   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Oct 31, 2013, 17:27:13
The exhaust reverse cone megas arrived today, I'm really pleased with them, seem to be very well finished. They came with a simple mounting bracket that would be too long no matter where they end up being fitted, so one job today was to make a couple of the temporary brackets with lots of holes so I can try different positions for the megas. So I made them quickly and simply from a scrap piece of alloy, no need to be any better as they'll be replaced with something much neater..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102001_zpsed49dc3b.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102001_zpsed49dc3b.jpg.html)

Making the tempory brackets
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead103006_zps16430975.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead103006_zps16430975.jpg.html)

That done, next job was to mount the coil under the tank. I marked out, punched and drilled a couple of mounting holes in the head steady. It places the coil quite close to the front cylinder head, but raising it up an inch or so would've kept it out of the air flow.. swings and roundabouts.. so I decided on the lower option in the end..  The coil is an aftermarket 3 ohm single fire unit (effectively its two coils in one), std Harleys use duel fire coils, with both spark plugs firing at the same time. Single fire is supposed to give a small performance gain, and at least my spark plugs should last longer. I'll be fitting a matching electronic ignition, which fits neatly in place of the points. Points ignition use a 5 ohm coil usually, which gives a weaker spark than a 3 ohm coil that modern ignitions can handle..

Engineers blue, helps to mark out where I need to punch a guide mark prior to drilling
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead103003_zps01ca464f.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead103003_zps01ca464f.jpg.html)

All done..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead103005_zpsf7bc1901.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead103005_zpsf7bc1901.jpg.html)

To make a start on the exhaust downpipes, we made these  collars in stainless, they are stepped inside, so they slide tightly over the exhaust tubing (to be welded), and over the engine exhaust stub. I preferred this method, rather than finding someone to expand the end of the tube, because I don't know yet which tubing I'm going to use at the moment..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead103002_zpsa02bdcf2.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead103002_zpsa02bdcf2.jpg.html)
 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Oct 31, 2013, 18:34:41
Skills & tools! :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 01, 2013, 12:25:31
Skills & tools! :)

Wish I had more of both  :)

Looks like my new silencers wont be too effective  ;)

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 01, 2013, 12:41:38
Looking great Man.
you keeping up here,and its enjoyable to follow along this thread.
Featherbeds are sooooooo beautyful.
Hope to have one rolling myselves in a couple of years.....
(Loud pipes saves lives)  ;D
keep posting!!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 01, 2013, 13:28:06
When I get chance I'll post a thread on my Guzzi Café build, which was 2/3 completed before I put it on hold to start this one. Since then I've decided to go in a different direction with the guzzi, but that's next years project  :)

This neat little petrol tap arrived, I did buy one last year, but I gave it to a mate who was desperate for a replacement for his Harley to make a trip. This one is nicer and not much more expensive...

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102002_zpsc883d319.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102002_zpsc883d319.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead104012_zps666fd06c.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead104012_zps666fd06c.jpg.html)   

I played around with the location of the megas, I'd prefer them to be higher and tilted up a bit more, but with the rearsets being so far back, its not practical as I'd be toasting my feet and melting the soles of my boots. Still haven't finalised where the downpipes will go, I need to make another trip to the exhaust pipe supplier for a few more bends with a tighter radius if I can get them. Current idea is to have the front pipe going beneath the engine and on to the LHS, while the rear will loop down and back to go into the RHS mega.   

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead104003_zpsbbd13d9f.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead104003_zpsbbd13d9f.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead104013_zpsc1e6706a.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead104013_zpsc1e6706a.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead104016_zps30a12c17.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead104016_zps30a12c17.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 06, 2013, 19:14:52
This is my second attempt at the exhaust, I had to stop and buy more stainless bends, as those I had were distorted in some of their bends. Not a problem under a car, but when polished on the bike they'd look crap. Its held together for now with tape and string, but tomorrow I'll get the first bends tack welded, then bring them home to check they are ok, before taking the remaining sections to the welder to finish the headers.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 06, 2013, 19:39:03
Who's tank is that on it? Is that a Hawg Halter caliper on that bike in the Norley shop?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: AgentX on Nov 06, 2013, 20:14:30
ummm, yes please.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 06, 2013, 20:20:04
Who's tank it that on it? Is that a Hawg Halter caliper on that bike in the Norley shop?

Tank is from Norley, I think they get them in turn from T.A.Baker   http://www.tabclassics.com/   who aren't too far away from Norley. The front end including the caliper on the black bike looks to be from the Buell its built from.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 06, 2013, 20:28:50
Tank is from Norley, I think they get them in turn from T.A.Baker   http://www.tabclassics.com/   who aren't too far away from Norley. The front end including the caliper on the black bike looks to be from the Buell its built from.

I see you are right, upon closer inspection it is a stock Buell caliper, it is very similar to the HHI 6 piston caliper.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 08, 2013, 12:20:29
The exhaust is pretty much done, though still needs to be polished, and one pipe under engine needs to be expanded to give me a slip joint. I'll weld on a couple hooks and use exhaust springs to hold it together next week.

One problem I had was that some of the bends I had to cut were deformed, which would've made welding them to a straight piece look awful, so they were binned..

Some bends were deformed when cut in half..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead107002_zps62336111.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead107002_zps62336111.jpg.html)

Using the good bends I did have, I could've gone for this option, as it involved a minimum of welded joints..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead107003_zps5620b29a.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead107003_zps5620b29a.jpg.html)

But it didn't look quite right, so I tried again and came up with this instead.. note all the string, tape and even an old tooth brush I used to hold everything in place, it was tricky with just one pair of hands
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead107007_zps6c2985d2.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead107007_zps6c2985d2.jpg.html)

A few more trips back to the welder and its done.. It would've been better if the megas were a little higher and tilted up, but the gearchange linkage means this is as far as they could go on the left and the right hand side had to mirror the left..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead107015_zpsac471645.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead107015_zpsac471645.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead107020_zps1135dd02.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead107020_zps1135dd02.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 08, 2013, 12:49:40
Left side pic?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 08, 2013, 13:23:35
Left side pic?

Its dark now, no lights where I'm working on the bike, so will take a pic of the LHS tomorrow.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 09, 2013, 13:08:22
LHS pic, not much to see, the downpipe just turns under the engine and goes forward. I still need to cut approx. 1/2inch from the end of the downpipe, to allow the exhaust to tuck in closer to the frame rail to give more ground clearance.   

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 09, 2013, 17:14:44
looking awesome! ;D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: john83 on Nov 10, 2013, 11:20:17
Very cool!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 10, 2013, 12:53:15
+1
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: cyclhed on Nov 10, 2013, 13:09:27
Cool stuff! Subscribed.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Erskine on Nov 10, 2013, 16:16:09
Subscribed.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 11:31:14
I refitted the rear brake, having got the bracket back. I'd lent it out to be used as template. Spent a long time looking at the exhaust, pity but its not quite right yet. The down tubes and megas need to be higher, for more ground clearance, to clear the rear spindle and to look better. I also noticed that the brackets holding the footpegs were flexing under my weight, which was amplified by the megas. They'd probably be ok, but since I wanted to move the pegs forward for comfort (they are along way back) and to give more room to raise the exhaust, I decided to make new brackets to move the pegs forward and modify the exhaust too. The red lines show what needs to be done, hopefully by the end of this week..


Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 11:52:53
I just noticed the mega tips are not parallel to each other, is there a way to "fix" that. Right now the right side is abut 4" shorter than the left and you plan on shortening it another  3-4" and the left only 1" compounding the difference.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 12:09:42
They would be parallel to each other when everything is tightened up, in the pics the mounting brackets and downpipes are loose, so the megas may be offset. One of the biggest headaches with making the downpipes is getting them spot on so the megas are the same angle and position. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 12:16:38
Everything in the pic looks like it is installed. The joint at the connection of the reverse taper is n line with the shock mount and the other side looks 4" in front of the taper, is there that much play in adjustment when tightened up? How will you move the rearsets, make a new shorter bracket?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 12:55:49
Everything in the pic looks like it is installed. The joint at the connection of the reverse taper is n line with the shock mount and the other side looks 4" in front of the taper, is there that much play in adjustment when tightened up? How will you move the rearsets, make a new shorter bracket?

I see how that looks now, the brake side mega looks like that partly due to the angle of the photo and because its header pipe under the engine is the one joint not finished yet, so its not in its final position. It needs a slip joint, either by expanding the tube or welding a sleeve onto one side of the joint. I held off on getting that done because I knew I may want to modify the exhaust once I'd given my self time to ponder it.

Edit to add.. yes I'll make new brackets, prob out of 10 or 12mm 7050 alloy plate, and reuse everything else. I should have done it months ago, but I liked the look of the LSL rearsets too much.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 12:58:05
Gotcha. And the rearset bracket question?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 13:00:30
you were too quick  ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 13:03:06
you were too quick  ;)

Was I too quick or were you too slow? Sounds like a challenge to me. ;D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 13:23:12
Hey I'm getting on a bit, us old folks aren't as quick as you young uns  :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 13:30:24
Hey I'm getting on a bit, us old folks aren't as quick as you young uns  :)

How old are you and just how young do you think I am?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 11, 2013, 13:39:04
Your only as old as you feel....  ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 11, 2013, 13:40:13
Your only as old as you feel....  ;)

Come on, answer the questions ;D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 12, 2013, 14:18:54
Made some progress today, but its feels like I've made one step forward and two back...

I finally found an exhaust specialist (Quill racing) who could expand my 16 gauge tubing, and a good job they did too..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead111002_zpsd3a3b2c5.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead111002_zpsd3a3b2c5.jpg.html)

This should have been the last piece of the jigsaw, but I wanted to raise the downpipes a little and tuck them in closer to the engine, in addition to bringing the megas forward to allow the rear wheel spindle to be removed without having to remove them first.

The RHS went ok, I cut 7cm from the downpipe, I'll get it welded when everything else is ready. Compared to how it was, I've gained ground clearance, can access the spindle and it looks better..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead111016_zpsbe59f651.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead111016_zpsbe59f651.jpg.html)

I also picked up a few stainless exhaust springs, which I'll use at the exhaust ports, I don't trust the way HD designed this, so going for a belt and braces approach..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead111017_zpsbe1521c4.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead111017_zpsbe1521c4.jpg.html)

What I didn't realise is that by moving the RHS mega forward and up slightly, it makes it impossible to do the same with the LHS mega, and still have them both at the same height and angle. I can do one or the other, but not both with the way the LHS downpipe has been made.  Its not a huge difference, but it needs to be fixed. Not sure how yet, may have to build the LHS all over again. :(

 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Nov 12, 2013, 15:24:54
your bike is looking really incredible ! personally I wouldn't worry about having them the same on both sides, after all your bike looks different on each side as it is...
 I think it is correct to have each pipe the same length but to have the muffler in identical position on each side BAH....
it is an asymmetrical; work of art it is made to be that way
  it's not like a parallel twin that is easy to have equal length both sides
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 12, 2013, 16:18:38
Having the mufflers asymmetrical on that build will make all the cool be overlooked by everyone that sees the bike.  You're on the right track correcting that issue. You know what you are doing , so continue on that track. You are the only one that can say what it was "made to be".
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Buster on Nov 12, 2013, 17:34:13
I just lost a few hours of my life going through this build thread in detail - fantastic work thus far! Your attention to detail is amazing, and I really like the way you are keeping the whole classic Triton look while incorporating the ironhead engine. Don't pay any attention to the people who feel the need to interject and critique every single post - I am really impressed with what you are achieving , especially the fact that you seem to be fabricating a lot of the parts yourself with a minimum of tools.

I built a Harley cafe racer a few years ago, but it wasn't even in the same league as yours:
(http://i247.photobucket.com/albums/gg131/xr1200/1200cafe.jpg)

(http://i247.photobucket.com/albums/gg131/xr1200/PacificCoast.jpg)

At any rate, keep up the great work - I'll be following this thread with interest!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Nov 12, 2013, 18:46:49
Having the mufflers asymmetrical on that build will make all the cool be overlooked by everyone that sees the bike.  You're on the right track correcting that issue. You know what you are doing , so continue on that track. You are the only one that can say what it was "made to be".
wrong
you can only see one side at a time most people wont even notice or care
besides a true race inspired machine is not built with emphasis on something like the mufflers "looking the same" on both sides that is putting looks ahead of pure function
maybe you best even up the pipes on your bike they don't look the same ::)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 12, 2013, 18:53:29
wrong
you can only see one side at a time most people wont even notice or care
besides a true race inspired machine is not built with emphasis on something like the mufflers "looking the same" on both sides that is putting looks ahead of pure function
maybe you best even up the pipes on your bike they don't look the same ::)

Mine are not intended to be, were not designed that way and are exactly as I wanted them. They would be if I had them split from side to side. When you have a bike the caliber of mine then I might listen to your criticism. You have nothing to offer when it comes to my bike.
Your theory of mufflers contradicts your criticism of mine, so which is it? Who are you to tell a builder how his build was intended to be. This guy has gone to great lengths to see that they are matched up. You think he should change that because of your critique? ;D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 12, 2013, 19:17:57
Hey guys, chill out  :), Its true that if you looked at the bike from either side, you probably wouldn't notice the difference in position of the exhaust. But from behind you certainly would. Though the point I was trying to make is that I'd know they weren't how I wanted them to be, so I'll keep going till I get them how I see them in my minds eye. I sat looking over at the bike earlier, and I think I have a solution.. then again a 2-1 would've been a lot easier  :P

There is always a trade off in Form Vs Function, in this case I'll gladly give up a couple of BHP to get it looking how I want. After all if I wanted function at all costs, I wouldn't be building a bike with an Ironhead 4 speed engine and a frame designed before I was born. I'd just go out and buy the latest ZX10R1GSXRCBRRRR, but where's the satisfaction in that that.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 12, 2013, 20:08:32
Hey guys, chill out  :), Its true that if you looked at the bike from either side, you probably wouldn't notice the difference in position of the exhaust. But from behind you certainly would. Though the point I was trying to make is that I'd know they weren't how I wanted them to be, so I'll keep going till I get them how I see them in my minds eye. I sat looking over at the bike earlier, and I think I have a solution.. then again a 2-1 would've been a lot easier  :P

There is always a trade off in Form Vs Function, in this case I'll gladly give up a couple of BHP to get it looking how I want. After all if I wanted function at all costs, I wouldn't be building a bike with an Ironhead 4 speed engine and a frame designed before I was born. I'd just go out and buy the latest ZX10R1GSXRCBRRRR, but where's the satisfaction in that.

I agree with this 100%. Is your bike gonna be fast? Yes. Will mine be fast? Yes. Will they hang with a Busa, hell no. But it's an apples and oranges comparison. I doubt the difference in pipe length will amount to one horsepower with what these motors make but in most cases a bike on the street rarely, if ever, sees 100% of what it is capable of. It's the dare to be different attitude that make these builds thrive. The fact that you are building something that will heavily out perform in every aspect that of the original bike.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Buster on Nov 12, 2013, 20:18:18
Your theory of mufflers contradicts your criticism of mine, so which is it? Who are you to tell a builder how his build was intended to be. This guy has gone to great lengths to see that they are matched up. You think he should change that because of your critique? ;D

This is an interesting retort, from a guy who can't let a single update from the OP go by without adding his two cents and a critique. I'd really love to just enjoy this build thread without the added 'value' of your running commentary, quite frankly.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Nov 12, 2013, 20:25:17
This is an interesting retort, from a guy who can't let a single update from the OP go by without adding his two cents and a critique. I'd really love to just enjoy this build thread without the added 'value' of your running commentary, quite frankly.

I have been a regular poster on this build since he started it on another forum over a year ago. I have asked questions at time but not told him how it should be built.
It's the internet, you can't have what you want.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: coyote13 on Nov 13, 2013, 12:27:22
I hate to post this and further clutter up a very good thread, but Marc, your tone comes off as being quite "holier than thou" a lot of times, and your incessant commentary (some good, I'll admit) is cluttering up an otherwise brilliant thread.  Buster has a point, you also have a point, but go back and read through some of your own replies with an open mind and you'll see that in many cases, Buster is right.

Food for thought, /soapbox
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: WeberKid on Nov 13, 2013, 13:13:20
When you have a bike the caliber of mine then I might listen to your criticism.

(http://assets.diylol.com/hfs/292/c65/05f/resized/jesus-says-meme-generator-jesus-says-don-t-be-a-dick-74f8fb.jpg)

I hate to post this and further clutter up a very good thread, but Marc, your tone comes off as being quite "holier than thou" a lot of times, and your incessant commentary is cluttering up an otherwise brilliant thread.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: AgentX on Nov 13, 2013, 22:57:28
Get a room.  More bike, please.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: andycafe on Nov 14, 2013, 04:08:12
Very cool mate  8) I like your ideas  ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Nov 14, 2013, 12:51:03
Get a room.  More bike, please.


^^^ This..  I dig the bike. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 14, 2013, 15:40:28
OK, todays progress, or lack of.. I needed to move the rear sets before doing anymore work on the exhaust. But I didn't know just where they should end up. So todays task was to make a couple templates in some scrap alloy, with a few different mounting holes, then I could try moving around the pegs until I was happy, and hopefully let me finally position the exhaust the way I want. This will mean making a new shift rod and modifying the downpipes yet again. Its not a problem, as I consider the bikes I build to be prototypes of themselves.. they always have to change and evolve.

Over at Jeff's workshop.. cut out two alloy 3mm plates from an old road sign, mark out where the holes should be..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102005_zps82bb73be.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102005_zps82bb73be.jpg.html)

Drill them clamped together, check and time for a teabreak..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102007_zpse8fc15c7.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102007_zpse8fc15c7.jpg.html)

Back home, the templates fit, though I needed spacers. I was considering making new brackets for the LSL pegs, but now I'll just make a pair of simple plates to move them forward. They'll be made a lot neater then these templates, from 12 to 15mm alloy, so the frame mounting bolts can be countersunk flush with the plate (so wont need the spacers). The alloy plate will be threaded to take the bolts holding the rear sets. This position seems to work ok, it should give me enough clearance to fit the mega the way I want..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102015_zpsfeba55a4.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102015_zpsfeba55a4.jpg.html)

Still got to get the downpipes right, but feels like I'm on the right track now. This is the tricky bit, to get the joint right as the downpipe comes up and out from the underside of the engine. Have to get the correct angle and position of the mega and give sufficient ground clearance..
 (http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102025_zps315e506a.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102025_zps315e506a.jpg.html)

While at the workshop, we extended one of the downtubes by inserting a two inch piece, just tack welded for now.. was going ok till the very last weld, when we blew a hole through the pipe. I'll cut out 5mm from this section and have it welded  up later..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102013_zps7f2e72dd.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102013_zps7f2e72dd.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead102014_zps8d124e55.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead102014_zps8d124e55.jpg.html) 
 
Title: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Rich Ard on Nov 14, 2013, 20:59:31
Ahh, that's a pisser. Are you going to be coating the pipes or leaving them raw?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: focusinprogress on Nov 15, 2013, 11:28:14
Tig welding without back-purging the pipe?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 15, 2013, 14:09:49
Tig welding without back-purging the pipe?

Yes, shouldn't really, but thought we'd get away with it for just a few spot welds, so I could go home and check the fit on the bike, before having the joints fully welded. Almost got away with it, only the last spot weld went bad. Its fixed now, so no problem.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 15, 2013, 14:13:58
Ahh, that's a pisser. Are you going to be coating the pipes or leaving them raw?

I'd prefer to leave them just linished, for an industrial look, but I'll probably have to polish them to match the chrome on the megas. I could get everything ceramic coated including the megas, but that would be a pity as the chrome is good quality.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: durp on Nov 15, 2013, 14:56:48
god this thread is makin me moist. I've loving all the work you're doing. Great job. I just started an ironhead project myself, can't wait to start design and fabrication after i get it runnin.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 16, 2013, 18:35:10
Thanks for the comments, I sometimes think I go into too much detail, particularly for the fairly simple stuff I do. Today, Geoff the welder was working on a weekend, so I popped over where he welded the last piece on the RHS pipe. I've learnt my lesson in not trying to do both sides at the same time. I've wasted hours trying to get both megas at the same angle and height, and changing both sides at the same time. With one side done (almost!) and fixed, I've now finally managed to match the LHS, which I'll get welded on Monday afternoon. The hooks to hold the exhaust springs have also been welded onto the exhaust. I was about to drill the holes in the cylinder head fins to take the other end of the springs, when my drill died..

Here's an action pic of Geoff welding my exhaust (surprised the camera could handle the intense light, I certainly didn't risk it). I asked about his old work bench, he did his apprenticeship on it, in a local brewery. When it closed, it came with him. BTW that old brewery had been there since the 1740s.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead117004_zps4a984450.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead117004_zps4a984450.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead117003_zpsa195ee3e.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead117003_zpsa195ee3e.jpg.html)

Been playing with the edit function in Photobucket..the new downpipes may not look much different, but every joint has been changed and rewelded..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/87f80238-d306-49bd-a6d1-3ba43861ce7b_zps6ee99e61.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/87f80238-d306-49bd-a6d1-3ba43861ce7b_zps6ee99e61.jpg.html)

My clip ons are 7/8 inch, in case I use HD std 1 inch hand controls (I had a set of German made RST controls left over from an old project), Geoff kindly gave me an off cut of 16 gauge 1 inch tubing, if I cut this in half lengthways, it should make the shims I need.. saves a few pounds on buying them..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead118005_zps8b4ceda9.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead118005_zps8b4ceda9.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: johnu on Nov 16, 2013, 18:53:45
That work bench is awesome, oh and the bike's not too bad either ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Erskine on Nov 16, 2013, 20:54:32
Great stuff!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: rundown on Nov 16, 2013, 22:12:36
Extaordinary build, Harly in a Norton, pretty much off the chart cool.  I hope you don't take the attitudes of some of the posters to heart, just raised by wolves. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: café (r)acer on Nov 17, 2013, 10:13:31
Thanks for sharing this build!
I've learned alot so far  :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 19, 2013, 12:28:37
The exhaust is finally done, still need to decide whether to polish the downpipes, but that can wait. Next job will be to make the real rear set mounts and exhaust hangers, in place of the temporary ones I've used so far. Also been thinking about where the battery is going to live. Ideally it should go under the seat hump, but there isn't a lot of room under there, so the back up plan was to mount it under the swing arm, behind the gearbox, as I'd seen a few Sportsters with the battery in that location, so should be enough room. My drop seat Harley has its battery under the swing arm (actually it sits in the swing arm), which has always been a PITA, as to access it, I need to remove the rear wheel, not ideal

I'd always intended to use a Lithium Iron battery, and for the Ironhead, I'd need the equivalent of a 20AH Yuasa lead acid battery. I could get a Shorai at a good price, but looking at it specs, it didn't look that much smaller than the Yuasa, though it is much lighter. With one of my exhaust downpipes running under the engine, I wasn't sure if there was enough room behind the gearbox to fit the Shorai, let alone a Yuasa.

I made cardboard copies of the three options, Yuasa, Shorai and Ballistic. Sure enough the Yuasa wouldn't fit, while the Shorai only just squeezed under the swing arm, a bit too close to the exhaust and rear tyre for comfort.  The Ballistic was so much smaller it would even fit under the seat, if it was recessed a little into the tray I'd made earlier. So that's what I'll do. The Ballistic isn't cheap, twice the price of a Yuasa, and I've read mixed reviews of Lithium batteries on bikes, but going to give it a try..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 22, 2013, 12:04:34
Got myself a new hand drill, so the exhaust springs are on now. Ordered a Ballistic Lithium battery, and dropped the stainless seat under tray off at Geoff the welders, where he'll add a 25mm deep pocket for the battery. Fingers crossed that'll allow enough room for the battery to live under the seat hump. Also ordered a universal throttle cable kit from Venhill,  to connect the Tomaselli throttle with the S&S Super E carb. The other Jeff is making the new rear set mounts from my design, it'll mean the original 'V' shaped mounts will be replaced completely, which will look better than the original plan. 

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 22, 2013, 13:47:22
While looking at Maxton's site (suspension gurus near me), I found this great little video.. the bike head for a little resort on the  coast, same place place as my frame was made..enjoy.. :)

http://vimeo.com/76807240
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 22, 2013, 13:55:13
Is that the trident that was featured in classic bike magazine a while back with that insane upswept exhaust?
Have such a terrible connection to the web,so i can`t load that vid!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 22, 2013, 15:36:33
Is that the trident that was featured in classic bike magazine a while back with that insane upswept exhaust?
Have such a terrible connection to the web,so i can`t load that vid!

Didn't see the magazine bike, but the one in the vid does have a 3-1 steeply upswept exhaust, similar to the other two bikes.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 22, 2013, 17:14:58
Yes it was,beautyful one that is.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 22, 2013, 18:18:15
Found out the bikes in the film were built by a workshop who also worked on my Ironhead before I got it (raked the frame, made the yokes and extended the forks).. small world. More info here...  http://www.malarkeyengineering.co.uk/21stchtml.html
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 22, 2013, 18:54:02
Remember from the article that the bluish/green trident produced 82 whp.
Thats nice performance of a 69/70 trident!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 25, 2013, 09:19:28
I got the seat under tray back, with its battery recess welded in place. Now all it needs is a Ballistic battery..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead124003_zpsf4530f18.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead124003_zpsf4530f18.jpg.html)

Also made a start on the new rear set mounts. I used a scrap piece of 10mm alloy and drilled the peg and frame mounting holes first. Then took it home to check it fits the frame ok, so now the rear master cylinder can be mounted, and the bracket shaped. The other side is easier to do, except it'll need a new shorter shift rod making. The socket head bolts will be counter sunk a few mm and their heads machined so they are almost flush with the plate.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead125006_zps9093d22c.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead125006_zps9093d22c.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead125005_zps3cfa9d69.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead125005_zps3cfa9d69.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 25, 2013, 12:21:50
Lppks stunning MR!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Nov 28, 2013, 21:13:16
Today with the arrival of my new Ballistic battery, my bike has lost another 11lbs, compared to the equivalent Yuasa YTX20BS (13.9lbs Vs 2.7lbs) or 1.2kg. I'm edging closer to the target of losing 100lbs compared to a standard XL1000. The new battery fits easily in the recess made for it, with spare room enough for some foam to cushion the vibes.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Nov 28, 2013, 21:24:33
nice 8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: durp on Nov 29, 2013, 03:02:54
Yes! I have the same battery for my goldwing bobber and my ironhead project. I swear by these things.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 01, 2013, 19:30:43
Yes! I have the same battery for my goldwing bobber and my ironhead project. I swear by these things.

Good to know, the only problem I've read about is that they don't like to be overcharged or drained completely (it kills them). May have to fit a little voltmeter, just to be on the safe side, my 888 has one and its comforting to be able to keep an eye on the Italian electrics.

Made a start on the cutting out the plates for the rear sets, and been trying to find a suitable pair of master cylinders (clutch and front brake), I'd like Brembos, but they are twice the price of Japanese Nissins on ebay. Nineties GSXR look to be a possible source, as they have angled master cylinders to suite clip ons.. Still looking.

Also I had to order a piece of alloy to make an air filter / Velocity stack, as I couldn't find anything suitable to liberate from Jeff's hoard. The S&S Velocity stack on the carb now is too long and has no filtration at all, I had it left over from an old project, so fitted it just to see how it looked. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: unclerob on Dec 01, 2013, 20:30:06
Just seen your thread....looking good! Interested because I once rode a friends Domi fitted with a WLA motor...it wasn't fast! Have you thought of using master cylinders from the early 80's Honda Shadow, can't quite recall exactly what they look like but I do remember that they are angled just right for clip ons!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: john83 on Dec 05, 2013, 17:10:37
Good to know, the only problem I've read about is that they don't like to be overcharged or drained completely (it kills them).

Yes, it does. I had one on my Thruxton and didn't realize my regulator was going bad. Drained it dead a couple of times and it stopped recharging. That was a costly mistake.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Dec 05, 2013, 17:38:30
Better check what kind of output your genny is throwing out with that then.  May be a simple fix of a different reg, or you may want to get a new low output genny from cycle electric.  The 6v on my 59xlh seems ok with its small battery, but my buddies '70xlh just eats smaller batteries with the 12v.. He's looking to upgrade (downgrade?) to a low output system for his. 

Common problem with genny HD's running non stock batteries.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 05, 2013, 18:40:59
Good info on the Lithium battery, the one I have is 12 cell, 20ah, so not that small really. Also I've fitted a modern aftermarket rectifier/regulator which replaces the geny end cover, but even so I'm now leaning toward fitting a voltmeter too.

Finally found a suitable pair of clutch / front brake master cylinders at a good price, not Goldline Brembos, as they were way over priced on Ebay. Went for a set from a Honda VTR SP2 instead, which fit the look I was going for.   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 08, 2013, 05:05:03
Finally got around to taking off the heads, as I wanted to replace the pushrod covers and maybe paint the heads silver/grey. I hate opening up an engine that runs ok, turns out for good reason. It was all going to plan, when I hit a problem. The new lower push rod covers wouldn't fit over the old (none standard) inner cover. This was a surprise, as I'd assumed even aftermarket inners would be the same, since they cant be seen. But no. This stopped the work dead in its tracks. I've ordered new inner pushrod tubes, which have to come from Zodiac in Holland, no idea how long that will take, hopefully not too long.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead127003_zpsefb38800.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead127003_zpsefb38800.jpg.html)

Heads look ok, not much carbon build up, and just a bit of rust near the exhaust port where the heat must have affected the powder coat, not as bad as they first looked. Not sure now if I should leave them black or paint them a silver/grey.

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead127004_zps86d96b8b.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead127004_zps86d96b8b.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 11, 2013, 11:39:47
The order didn't take long to arrive, so got busy cleaned and painted the heads, new pushrod covers, head bolts and rocker dome head nuts..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead128008_zps9c466b73.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead128008_zps9c466b73.jpg.html)

The paint was taking its time to cure, so helped it along with 30 mins at 80c..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead128006_zps6ba9bd9e.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead128006_zps6ba9bd9e.jpg.html)

Got this stainless starter button, think I'll fit it here, on the top motor mount, I may be able to fit the horn button there too, which will keep the wiring out of sight..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead128018_zps8c62c075.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead128018_zps8c62c075.jpg.html)

Also been thinking about drilling/machining the sprocket cover.. hence the marker pen dots in the photo. Not sure yet, I don't want to go too far, as I want to keep the top half to stop chain oil being flung all over the place..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead128014_zps8bff4b07.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead128014_zps8bff4b07.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: durp on Dec 11, 2013, 11:40:39
beautiful
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: durp on Dec 11, 2013, 11:41:02
Are you stickin with the stock points?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: squirley on Dec 11, 2013, 11:57:41
This is looking great!
Where did you pick up the stainless push button from?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 11, 2013, 12:12:49
Are you stickin with the stock points?

From the pic it looks like you have a Compufire ignition going in.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 11, 2013, 12:39:56
This is looking great!
Where did you pick up the stainless push button from?

From the Zodiac catalogue (euro HD custom parts), you can view their products on line.. just google 'Zodiac Harley'

Don't like Points, converting to single fire electronic ignition (in cone), using 3 Ohm coils
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Cuba Libre on Dec 12, 2013, 06:00:21
Got this stainless starter button, think I'll fit it here, on the top motor mount, I may be able to fit the horn button there too, which will keep the wiring out of sight..
That's a very nice touch. I'm all for the clean and... wireless... look. I assume that's what you're after as well, especially for the handlebars, right?
But, doesn't the horn button need to be near your thumb?
What other switches will you be fitting and where?

M.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 12, 2013, 13:01:02
That's a very nice touch. I'm all for the clean and... wireless... look. I assume that's what you're after as well, especially for the handlebars, right?
But, doesn't the horn button need to be near your thumb?
What other switches will you be fitting and where?

M.

The rules state it needs a horn, but not where the button goes, so its going somewhere out of the way. I cant remember the last time I used a horn on a bike, you wouldn't hear it over the exhaust noise in any case  ;D. To pass its MOT (annual inspection) all it needs is a horn and lights (and brake lights).. and they can be on all the time, don't even need high/low beam. The ignition key has three positions like most HDs, on, off and lights so that's all its having. There will be no buttons on the bars, no indicators, no kill switch and no mirrors. I can do this as the bike has a 79 plate, so many modern regulations don't apply. I still have to find a home for the idiot lights, haven't decided where they will go just yet.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 13, 2013, 07:11:17
The VTR Firestorm master cylinders I got off Ebay arrived, just had to order a replacement brake lever as that was missing. I wanted to use Goldline Brembos, but they were three times the price, even for rough ones with no levers and pots. Not sure about the plastic reservoir pots on these, they look a bit out of place. There are loads of aftermarket ones, or may try to make a pair to match the clocks. Looks like I've sold my Triumph Speed Triple this week, so progress should speed up a bit when I get the money from the sale.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: mechdesign2k4 on Dec 13, 2013, 09:15:23
Nice work! Great Build!!!!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DesertKZ on Dec 13, 2013, 13:34:59
Awesome, I want a harley powered cafe before I die. 8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 13, 2013, 20:54:19
Awesome, I want a harley powered cafe before I die. 8)


I weighed mine today on an accurate set of racecar scales. How are these for some numbers:
111lbs front, 156lbs. rear, 64lbs on the kickstand for a total of 331lbs.

(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/get-attachment56.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/get-attachment56.jpg.html)

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 14, 2013, 05:53:45
Impressive, was that with all fluids and running? Where has it lost the weight?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 14, 2013, 12:27:58
That is without fuel/oi so with 5 gallons and 3 quarts of oil add another 36lbs and she sits near my goal weight of 360lbs wet.  Lighter new tires without the old tubes, different tank, metric instead of heavy Harley handlebar controls. It all adds up a bit at a time. I can't help but pat myself on the back for achieving an almost impossible weight for a street Sportster that once weighed in the neighborhood of 540lbs.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Dec 16, 2013, 18:08:16
330 lbs with that kind of torque will be a blast to ride!

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 16, 2013, 18:11:30
330 lbs with that kind of torque will be a blast to ride!
Ya buddy. :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 18, 2013, 09:21:33
A few more jobs done...

The new rear set brackets are done (still need to make the brackets for the silencers), and polish them later..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead132002_zps6eef99b3.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead132002_zps6eef99b3.jpg.html)

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead132003_zps59da68d9.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead132003_zps59da68d9.jpg.html)

Machined a hex on the clutch slave cylinder, to fit a 30mm socket, as otherwise it needed a strap wrench to tighten it.. looks more interesting too

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead132004_zps92edbd38.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead132004_zps92edbd38.jpg.html)

Starter button is fitted in the top motor mount..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead132007_zps35b32fc6.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead132007_zps35b32fc6.jpg.html)

I've had this old oil filter mount for ages, it came off my old 1970 Ironhead, I wasn't going to use it, as I thought getting a suitable oil filter would be difficult and expensive, as its different from modern Harleys. But it turns out its the same filter as used on many modern Ducatis, my local bike shop had them in stock. I just need to find out the centre to centre distance between the lower bolts rear engine bolts, I cant measure it with a vern without taking the bike to bits. The bracket is so thick so I can use countersunk bolts to fasten the filter to the bracket..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead132023_zps4f8064c4.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead132023_zps4f8064c4.jpg.html) 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: CafeRacersUnited on Dec 18, 2013, 17:27:18
Great project. Inspiring to see how make everything!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 19, 2013, 13:17:29
I can only make pretty simple stuff at home, but today I wanted to make a front 'buckle' to fasten the front of the tank strap to the frame. I'd seen one for sale, which was very nice, but expensive..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/2015814_zps23dbeb80.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/2015814_zps23dbeb80.jpg.html)

So with an offcut of alloy plate, I made this, with just a hacksaw, a drill and a file. It needs longer socket heads to take the 1 1/2 inch tank strap, then I'll make the spacers to keep it centred on the frame tab, and maybe do a little more work to the side plates. Cost only time. Also ordered a 3 1/2 inch diameter by 3inch deep billet of alloy today to make a new air filter/ velocity stack. 



Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SF on Dec 19, 2013, 16:31:40
very cool build like the old iron getting back in the wind
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Erskine on Dec 20, 2013, 17:04:52
Your build continues to be cryogenically cool.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 25, 2013, 10:13:15
Since its xmas, bought a present for the bike... some debate about how useful it'll be on an old Harley, which run with very low oil pressure when hot. But its reassuring to know oil is getting to the top end, and it'll be getting an oil pressure light too..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead135b001_zps589e957d.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead135b001_zps589e957d.jpg.html)

Not the most obvious location, but really only need to see it on start up..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead135b007_zps9356191b.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead135b007_zps9356191b.jpg.html)

Should have the last few machining jobs done by early Jan, then the bike will be dismantled, followed by a little welding on the fame, then powder coat, then the final build can begin. There are still problems to sort out.. will the hydraulic clutch conversion work? and how to align the chain sprockets, as they are about 8mm out. The easy way would be to move the rear wheel over to the left by 8mm, but that's a last resort.

Or the front sprocket could be moved out 8mm, that would be best, except there isn't enough 'spare' thread on the output  shaft, to put a spacer behind the sprocket. The usual solution is to fit an offset front sprocket, which was my first thought. But it seems they aren't available for Ironheads (at least none I can find), as they are for later Evo Harleys. One more option.. weld two sprockets together, with the inner having its teeth machined off, and the outer having its centre removed.     
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Union Jack on Dec 25, 2013, 11:49:52
How you are going to make the tank's strap? will it be alloy? leather? I need to make one also. I want it to be alloy but I'm not sure which kind.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 25, 2013, 12:36:29
I have one already from Unity Equipe, its polished stainless. It came with a little hook and two pop rivets, you need to rivet the hook unto the strap at the right spot, so the hook links unto the rear buckle with the correct tension. Also got a strip of matching foam to protect the tank. Seems odd, but Unity don't sell a front 'buckle' for their straps, so I'm making one instead. Depends on the look your going for, but I feel a leather strap would work well, maybe use an old belt, or get one made to size, it shouldn't cost much. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 25, 2013, 13:05:39
You need to replace the 100psi gauge with one that only reads to 15-30. The factory manual says "Under normal riding conditions oil pressure will vary from 10-14lbs and at idle 3-7lbs." I doubt a 100psi gauge is very accurate at 3-14psi. I've determined with such low pressure and such a variance that the idiot light is more important just to know when you no longer have any. I understand that because of the way the Harley lubes things that, unlike modern bikes, you go a few further miles with no oil pressure before causing major damage. Are  you mounting it in the allen set screw on the front of the rocker box?
I think this one would be ideal for us. It may get pegged on the top now or then but I'd rather see pegged at 15 instead of reading zero:

http://www.ebay.com/itm/Direct-15-PSI-fuel-oil-air-or-hydraulic-pressure-gauge-/260437675313?pt=Motors_Car_Truck_Parts_Accessories&hash=item3ca34b8d31&vxp=mtr

Free UK delivery:

http://www.ebay.com/itm/50mm-Pressure-Gauge-Rear-Entry-0-15-PSI-AIR-AND-OIL-Free-UK-Delivery-/310370447846?pt=LH_DefaultDomain_3&hash=item48438531e6
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 25, 2013, 13:13:29
They do make offset trans shaft sprockets. I recently ordered a non offset sprocket and ended up getting sent an offset that the seller didn't know was offset. Let me find it and I'll tell you the offset and tooth count on it. If it will work for you you can have it for the cost of shipping.

Edit:
It's a 22t with a 1/2" offset. It could easily be cut down to 8-10mm on a at lathe. It's for an early XL.

22t-1/2" offset on left and 23t stocker on right
(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/photo9.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/photo9.jpg.html)
(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/photo10.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/photo10.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 28, 2013, 14:45:59
From cold my last Ironhead showed 50 to 60 psi on a similar pressure gauge, before dropping down to less than 10 when fully warmed up. The gauge can be attached via the allen screw on the front of the rear rocker box, and it would've been by now if the set screw hadn't been chewed up and impossible to remove. When the engine comes out of the frame in a couple of weeks, I may remove the rocker box and drill the set screw out. Or I may save the hassle and plumb it in elsewhere.

As for the offset sprocket, they aren't available anywhere in the UK, and look expensive on US ebay. Thanks for the offer of yours, but I already have a couple of sprockets, so it'll cost me nothing to sort it out. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Dec 28, 2013, 14:51:53
I run a line directly off the oil pump on my Ironhead.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Dec 28, 2013, 14:56:12
Maybe these guys can help ya http://pbisprockets.com/
Nice progress MR.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SF on Dec 29, 2013, 00:47:58
Can I ask you... Your frame looks to be brazed, do you prefer it over tig?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 29, 2013, 08:17:49
Can I ask you... Your frame looks to be brazed, do you prefer it over tig?

The frame isn't brazed, its 'gas bronze welded' according to Norley. I have no preference either way, so long as the welding is neat and well done, though the gold joints look cool. I'm still pondering whether to have the frame powder coated traditional black or clear. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Dec 29, 2013, 08:21:00
That beauty cant wear anything but clear ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 29, 2013, 12:08:53
I agree, put a clear coat on it and show it off, do anything but what everyone else does to keep in line with the uniqueness of the bike. I made a point of no black and no chrome on my bike.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SF on Dec 29, 2013, 14:15:01
I think it looks great with a clear coat. I'm trying to find some one to do the same on a springer I'm saving with radius rods
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: downtown809 on Dec 29, 2013, 14:39:11
As long as we get to vote, Clear..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Green199 on Dec 29, 2013, 14:46:32
Wow....what a fantastic build! Definitely...DEFINITELY....clear the frame...would be a shame to cover some of its uniqueness with a standard black coat.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: kiwi60 on Dec 29, 2013, 19:02:57
IMHO I'd say go clear; if you can bring the rest of the metal back to a silver finish as it looks black in the photo's - this would give a classy silver / gold contrast, otherwise all black.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Dec 29, 2013, 19:16:37
yeah nice clean fresh beads a blastin then a clear will make it sparkle :D
that would be hawt 8)
Title: Re: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: TriBSA Chas on Dec 29, 2013, 19:22:32
The frame isn't brazed, its 'gas bronze welded' according to Norley. I have no preference either way, so long as the welding is neat and well done, though the gold joints look cool. I'm still pondering whether to have the frame powder coated traditional black or clear.

I don't know what steel is used for your frame but the original manx featherbed frames used Reynolds tubing and Reynolds recommended gas bronze welding over welding because the heat from welding adversely affected the properties of the steel alloy used.

Sent from my Nexus 7 using Tapatalk

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Dec 29, 2013, 19:54:06
but it is not technically "welded" anyway, it is indeed brazed
certainally doesn't take anything away from the beauty or integrity of the finished work
 but welding only happens when the parent metals are heated to a molten state and fused
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Dec 30, 2013, 01:02:54
yeah nice clean fresh beads a blastin then a clear will make it sparkle :D
that would be hawt 8)
No it won't. Once you put clear on the metallic sparkle look of the bead blasting the light reflection goes away and it just turns a dull gray color. When I bead blasted my frame and it came back from the blaster that's exactly what I said, just clear that, it is beautiful. Unfortunately it doesn't work out that way with paint or powder.
Title: Re: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 30, 2013, 09:36:13
I don't know what steel is used for your frame but the original manx featherbed frames used Reynolds tubing and Reynolds recommended gas bronze welding over welding because the heat from welding adversely affected the properties of the steel alloy used.

Sent from my Nexus 7 using Tapatalk

They were made from Reynolds 531, which is still being manufactured but to special order only. The closest modern equivalent is BS4t45, or T45 for short, which my frame is made from. Interestingly Reynolds have developed new tubing materials, 853 and 953 which are being used to build prototype GP2 frames.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 30, 2013, 09:44:50
I don't want a bling finished frame, if I did I'd get it nickel plated, that would be too much with the polished alloy tank. The frame tubes have a dull brownish finish, as a anti corrosion coating I imagine. I removed some of this with wet and dry as a test, and if I kept going it could be polished, not sure if the powder coat would adhere to a polished frame. They normally bead blast frames before powder coating, that would probably remove the brown coat and leave a matt silver finish, need to talk to the powder coat man in the new year, see what's possible.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Dec 30, 2013, 09:49:12
You got one of the most beautiful frames i can think of. 8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SONIC. on Dec 30, 2013, 12:17:08
you can powder over polished metal no problem, it just needs to be thoroughly cleaned of all polishing compound and grease beforehand.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 08, 2014, 16:00:50
Next week the bike will be dismantled and the frame taken to be powder coated, still lots of work to do, but most of that can be done when the bike is back together again. In the meantime, I've been doing a few small jobs, one of which is to do something about the one off brass acorn nut on the engine, which covers the hole left by not having a rev counter cable (I'll be using an electronic tacho in any case).

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead135010a_zps9d0d1ba8.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead135010a_zps9d0d1ba8.jpg.html)

It didn't look right, more 70's chop than café, I wanted to replace it, maybe with a more suitable stainless cover. Having taken it off, I was surprised to find the this acorn nut was actually part of the rev counter drive, rather than a simple nut. So we machined the 'acorn' flat as possible, just need to polish now..

(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead138005_zps9ff70221.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead138005_zps9ff70221.jpg.html)

Machined the 'acorn' back..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead138007_zps7dd087b1.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead138007_zps7dd087b1.jpg.html)

Also got this alloy, to make a new smaller velocity stack, that's a job for another day ..
(http://i1122.photobucket.com/albums/l529/Merch131ho/Ironhead/Ironhead138002_zps481fedd6.jpg) (http://s1122.photobucket.com/user/Merch131ho/media/Ironhead/Ironhead138002_zps481fedd6.jpg.html)   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 08, 2014, 16:12:21
As Sonic mentioned, we coat over polished aluminum, stainless, and chrome/ nickle plating all the time with clear and candy colors.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 08, 2014, 19:13:39
Was that acorn unit a cable delete part? If not, how did the cable attach to it?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 08, 2014, 20:05:47
Was that acorn unit a cable delete part? If not, how did the cable attach to it?

The acorn dome screws into the thread that would normally be used to secure the tacho cable. No idea where it came from, looks to be a one off, based on the way its made.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 08, 2014, 21:59:56
The acorn dome screws into the thread that would normally be used to secure the tacho cable. No idea where it came from, looks to be a one off, based on the way its made.

Looks like it might be a long shaft, acorn top lug nut someone may have modified to work.
Shaft like this with acorn top in brass:
 (http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/mdqcTyrOyiDzO3hu7t812iA.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/mdqcTyrOyiDzO3hu7t812iA.jpg.html)

(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/acorn-cap-nuts-500x500.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/acorn-cap-nuts-500x500.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Jan 09, 2014, 17:13:22
   
You mean it costs 59,338.28 NOK to title a bike with a built from scratch frame?!?  ???
Easy :( depends on the amount of hp in the engine!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Jan 11, 2014, 10:57:49
Easy :( depends on the amount of hp in the engine!
$10.000 usd in taxes alone to title a new build is just INSANE! 
Sounds like if you were to build a 400HP Street Rod you would need to take out a Mortgage!   :o
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Jan 11, 2014, 12:26:38
$10.000 usd in taxes alone to title a new build is just INSANE! 
Sounds like if you were to build a 400HP Street Rod you would need to take out a Mortgage!   :o
I did some further research and the taxes depends on both hp and year of the engine +weight of the final product..
But the costs are insane if you dont have a title to begin with!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Jan 12, 2014, 08:33:16
Regarding the frame finish . . . one of my favorite bikes below with what look like nickel- a link at least, not sure how to post the picture.

I did a CB350 frame in bare polished metal and then clear powder- it did not adhere correctly and cracked in lots of spots.  The coater had never done one and the price was right so I went for it, trial and error, right?  Maybe your coater has better knowledge.  I did a bare polished metal tank and had my local body shop clear it- same thing and even peeled off on spots.  The shop owner talked to his supplier before hand and he said the clear would not adhere well as it was too smooth and there was no primer or sealer I think it was.  I had him do it anyway and it held up pretty well but not a long-term thing and you had to be very careful with it.

My opinion, as beautiful as a frame might be, it should be black . . . although the nickel below is gorgeous:

3rd post down:

http://www.hondashadow.net/forum/53-general-discussion/101574-kawasaki-w800-very-nice-2.html

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 12, 2014, 12:40:28
Regarding the frame finish . . . one of my favorite bikes below with what look like nickel- a link at least, not sure how to post the picture.

I did a CB350 frame in bare polished metal and then clear powder- it did not adhere correctly and cracked in lots of spots.  The coater had never done one and the price was right so I went for it, trial and error, right?  Maybe your coater has better knowledge.  I did a bare polished metal tank and had my local body shop clear it- same thing and even peeled off on spots.  The shop owner talked to his supplier before hand and he said the clear would not adhere well as it was too smooth and there was no primer or sealer I think it was.  I had him do it anyway and it held up pretty well but not a long-term thing and you had to be very careful with it.

My opinion, as beautiful as a frame might be, it should be black . . . although the nickel below is gorgeous:

3rd post down:

http://www.hondashadow.net/forum/53-general-discussion/101574-kawasaki-w800-very-nice-2.html


Not everyone has their post counts per page the same so when I go to the link I don't see what you are referencing. Which post # is it? I think you mean the Triton in post#12 (2nd post on page), Triton frames are almost always nickle plated.

(http://i253.photobucket.com/albums/hh79/o1racing03/Creative%20Candy%20Album%20II/Creative%20Candy%203/TRITON091.jpg) (http://s253.photobucket.com/user/o1racing03/media/Creative%20Candy%20Album%20II/Creative%20Candy%203/TRITON091.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Jan 12, 2014, 16:19:13
Rickman frames were pretty that way as well. ;)
 
(http://raresportbikesforsale.com/wp-content/uploads/2012/07/Rickman_Frame_1-600x402.jpg)
 
(http://raresportbikesforsale.com/wp-content/uploads/2012/07/Rickman_Frame_181.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Jan 12, 2014, 18:45:11
That Triton is the one . . .  but, I haven't seen many featherbed frames nickel plated.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 12, 2014, 19:49:49
That Triton is the one . . .  but, I haven't seen many featherbed frames nickel plated.
You're probably correct. I was thinking of Rickman and Trackmaster frames that are almost always Nickel plated unless you ask them not to plate it.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Jan 12, 2014, 20:14:21
Anyone know about what it would cost to nickel plate a frame the size of a wideline featherbed with swing arm? 

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 12, 2014, 20:34:53
Anyone know about what it would cost to nickel plate a frame the size of a wideline featherbed with swing arm?
Depends on the platers in your area. Trackmaster gets $350 to Nickel plate a frame.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Jan 12, 2014, 20:50:48
I know nothing about it- how does it compare to chrome?  Durability? 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 3DogNate on Jan 12, 2014, 23:40:23
Depends on the platers in your area. Trackmaster gets $350 to Nickel plate a frame.
My buddy is building a cool Triumph Tracker with an original Trackmaster frame... I did the paint job on it...
(http://i488.photobucket.com/albums/rr249/renegade900/Paint/C6AD8A67-6DAD-46B0-94EA-24E4CB30743B_zpscv50gtnz.jpg)
(http://i488.photobucket.com/albums/rr249/renegade900/Paint/CBBF4964-4502-4659-B4D3-8F9136FFB9FC_zps1bgcmika.jpg)

I know nothing about it- how does it compare to chrome?  Durability?
Chrome is much harder than Nickel, it's a different look too... warmer in color. Nickel holds up well though... you can see the difference in the photos above between the nickel frame and chrome parts. That frame is nearly 35 years old and looks great in person.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: downtown809 on Jan 12, 2014, 23:52:50
I know nothing about it- how does it compare to chrome?  Durability?

I am not an expert but here goes.
When parts are plated by a reputable shop they are prepped, plated with copper as a base coat to prevent rust, then a layer of nickel then a layer of chrome.
I have had two tanks done in nickel and there is a richness to it, not quite the shine of chrome. (http://i1149.photobucket.com/albums/o593/downtown809/IMAG0101_BURST002_zps0bbb3bf1.jpg) (http://s1149.photobucket.com/user/downtown809/media/IMAG0101_BURST002_zps0bbb3bf1.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 13, 2014, 01:48:54
Downtown beat me to it , but like he said , a good chrome job is called triple plating because it starts with copper then the nickel and then the chrome which is much harder and brighter than nickel
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Jan 13, 2014, 07:15:14
Cool, I like the look of the nickel plate.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: rundown on Jan 13, 2014, 10:49:15
Does anyone plate motorcycle parts in Nickel Boron?  This is used extensively with firearms, has the advantage of being thin, naturally lubricious, and easy to clean.  I use it in  number of rifles and it makes cleaning the "crud" out of a gas AR much easier.  Use on parts like swing arms sounds like a natural.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: RustyOlive on Jan 13, 2014, 12:03:49
Most of the chrome on the 305 was stripped and nickle plated.
Turned out really nice. Has a warmer tone.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Mike Lawless on Jan 13, 2014, 12:07:32
I've been following this thread with immense fascination.

Question...
Are there any US outlets for the Norley frame or are there any comparable US made frames?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 13, 2014, 14:14:28
I've been following this thread with immense fascination.

Question...
Are there any US outlets for the Norley frame or are there any comparable US made frames?

Found this place on google.. http://www.norleycaferacer.com/
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Mike Lawless on Jan 13, 2014, 14:30:23
Thanks.  I saw that too. No frames listed for sale, complete bike only it seems.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Jan 13, 2014, 14:32:37
Thanks.  I saw that too. No frames listed for sale, complete bike only it seems.
That is Santiago Choppers of CafeRacer TV fame. I believe they get their frames from the Norley factory in the UK.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Mike Lawless on Jan 13, 2014, 15:47:49
I see. I haven't watched much of the Cafe Racer show. Thanks for the info
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 14, 2014, 05:43:41
Ref Nickel Plating, last time I checked it cost around 3 times the price powder coating. Also its very thin, Nickel plating (and chrome plating) will show up every flaw and poor weld on a frame.

It seems I've maxed out photobucket's 10gb monthly limit on here, not too worry, the pics will show again on the 19th when the monthly allowance resets.

Finally wheeled the bike out from where I built it, as I'll need more elbow room when it comes to taking it apart. Here it is next to my 93 888 SP4 rep..  The footpegs are missing as need them to make the exhaust brackets. The tank strap has been cut to size and its hook riveted, works ok, but breaks up the lines of the tank to me. Maybe something to change later, in the meantime still lots to do to get it on the road by my self imposed deadline of April.

   
 
 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Floegstad on Jan 14, 2014, 15:12:05
I love the looks of both of your bikes mister!! :) :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 19, 2014, 05:25:30
Made a start machining the new velocity stack, just drilled it to match the size of the S&S carb so far..


With the Ironhead now in my garage, makes it easier to work on. Got the sprockets lined up, they weren't as misaligned as I first thought, so only needed a small spacer behind the front sprocket.

Finally one of the last jobs to do before the bike is taken apart for powder coating is to make the exhaust brackets. These are a bit trickier than usual as they need to be mounted to the frame via two bolts, not just one. This is because they sit almost parallel to the ground, at an acute angle to the silencers so they need to be sturdy. They are made from 10mm alloy plate, they'll sit behind the footpeg mounts (not in front as in the photo), and once drilled and shaped they'll need to be heated and bent to take up the 20mm offset to the silencers..

Title: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: freedomgli on Jan 19, 2014, 11:11:56
Awesome Norley! I just read through your entire build thread and it's absolutely fantastic!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 23, 2014, 11:58:06
Couldn't do much this week, waiting on some help to lift the engine out of the frame, so I decided to weigh the bike before it comes apart. I used a couple of bathroom scales under each wheel, then swapped them around to check if there was any difference in readings.. there wasn't.

The bike was weighed without oil or fuel...  Front weight = 185lbs, rear = 202lbs   total 387lbs

4 litres of oil weighs 3.7kg or 8lbs (I checked), while half a tank of fuel will be around 20lbs...  gives 415lbs ready to ride. I was aiming for 420lbs, so happy with that.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Cuba Libre on Jan 27, 2014, 10:52:52
There's a reason these are called featherbeds... ;D

M.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 27, 2014, 13:48:29
There's a reason these are called featherbeds... ;D

M.

The name came about when ...Harold Daniell was a successful Isle of Man TT racer with three victories and several placings in the Tourist Trophy races and the Manx Grand Prix. After testing the new Norton frame in 1950 he declared that it was like "riding on a featherbed" compared with riding the "garden gate'' Norton — and it has been called the featherbed frame ever since.

Here's a photo of the LHS.. exhaust mounts all done now..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Jan 27, 2014, 16:09:22
She's going to be a handful for sure.
Absolutely gorgeous
Let me know when I can nominate her for BOTM... so deserving
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Jan 28, 2014, 15:59:29
She's going to be a handful for sure.
Absolutely gorgeous
Let me know when I can nominate her for BOTM... so deserving


Agreed.... Sure to rattle some cages!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: coyote13 on Jan 28, 2014, 19:27:00
::starts slow clap::

I know she isn't finished, but I figure if I start the slow clap now, the crowd will be roaring by the time you're done!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 31, 2014, 20:31:40
Photobucket has maxed out again (all the photos will reappear on the 19th), so I'll try using attachments instead..

Found a hardened steel pin that just happened to be the right size to act as the clutch pushrod, which saved some work.. The one off slave cylinder is shown next to the original cable operated ball and ramp clutch actuator.

While my mate Jeff did a great job machining a new velocity stack for me, from solid billet. Just need to slim down the base a few mm (make sure it doesn't block the vent arrowed) and polish it..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 31, 2014, 20:36:44
And here's the bike for those who haven't been to the thread before

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DrJ on Feb 01, 2014, 01:40:58
The Tritoneers are gonna call sacrilege on me for saying the best looking motor for a featherbed frame is the Harley ironhead.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Feb 01, 2014, 08:06:40
Beautiful, just beautiful.  The lines are great and although I am not a fan of a Harley, that engine sure looks nice in there.  Good job.

I am not sure J, I still like a pair of preunits . . .  ;)

(http://i1126.photobucket.com/albums/l606/Thrux1/Tritons/Tritons012_zpsa24fdedc.jpg) (http://s1126.photobucket.com/user/Thrux1/media/Tritons/Tritons012_zpsa24fdedc.jpg.html)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 01, 2014, 17:48:41
It would've been easier to use a later Evo 883 or 1200 engine, but they didn't look quite right to me, too modern to suite the Norton frame. The Ironhead fills the frame nicely, the old Triumph engines look a little small in a Triton, with too much space around them.

Today made a points cover, I had one made for a Big Twin, but they have the two mounting holes horizontal, while Sportsters have theirs vertical (No idea why). I started out by hacksawing out a raw disc from some scrap 6mm plate, drilled and countersunk two mounting holes, then handed it to Jeff who machined it round in the lathe, added a bevel around the edge and machined the face smooth. I didn't polish it as I want to get it engraved.

To hold it he couldn't drill a centre hole, or hold it in the chuck. I was surprised how it was done. He used two thick alloy discs, both a little smaller than the points cover, pressed tightly either side of the cover. One disc was held in the chuck (the part that spins) and the other was pushed hard against the front of the cover and held by the lathe tailstock. Very clever, I'd never had thought of doing that.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: andycafe on Feb 01, 2014, 20:51:02
Yip this is looking sweet  8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DrJ on Feb 02, 2014, 02:10:08
It would've been easier to use a later Evo 883 or 1200 engine, but they didn't look quite right to me, too modern to suite the Norton frame.

And the belt drive just wouldn't look right.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: WeberKid on Feb 04, 2014, 18:19:25
And the belt drive just wouldn't look right.

neither of those engines come with a belt drive.  If I were going to put an engine in a norton frame, I'd def go with an evo over an ironhead, but that's probably on account of how much my current bike leaks oil.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 04, 2014, 20:29:55
neither of those engines come with a belt drive.  If I were going to put an engine in a norton frame, I'd def go with an evo over an ironhead, but that's probably on account of how much my current bike leaks oil.

Most 883 and 1200 XLs got belt drive in 1991, and all by 1993, though its not difficult to convert them back to chain drive. Evos would be easier to tune, more powerful and easier to live with for sure.

Back to the bike, I took it apart yesterday, the frame is having a little work done at the welders before it goes to paint. While I'm in the middle of the tedious job of polishing all the alloy parts.. yokes, rear sets, motor mounts... and the tank and stainless exhaust pipes.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: kiwi60 on Feb 05, 2014, 04:03:59
If your ever looking for an Ironhead belt drive, check out Karata.
I had one on my XLX45, no problems at all. :)

http://www.karata.com/primary.htm

They say out of stock, but you never know, they might have a production run scheduled.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: WeberKid on Feb 05, 2014, 09:40:44
Most 883 and 1200 XLs got belt drive in 1991, and all by 1993, though its not difficult to convert them back to chain drive. Evos would be easier to tune, more powerful and easier to live with for sure.

ohhhhh - final drive.  sorry - I had an idiot moment.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: kiwi60 on Feb 05, 2014, 13:51:06
Belt final drive, hmm never considered that, never had one on any of my bikes.
Besides, a good quality chain will last a long time if you look after it, it transmits power more efficiently, and it just looks better  IMHO   8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 05, 2014, 14:31:31
Belts have their place, they last along time normally. I converted my Big Twin Evo to chain drive after this happened for the third time..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 05, 2014, 14:41:22
Here's a rare pic of yours truly doing some work, polishing the alloy parts, filthy job, hate doing it, but better than paying someone else...

Laid out all the parts that came off the frame, helps not to get anything mixed up.. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 19, 2014, 15:49:19
Finally got the welding completed on the frame (for the rear light and oil tank mounts), and took it to be powder coated today. Should be ready in ten days or so, which should give me the time to finish a few jobs before the final assembly begins. The velocity stack is finished, and it'll stay until I find an air filter that looks right for the bike. Bought an alloy front fender, its just the blade so need to make a some kind of mount/fork brace for it soon.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Feb 28, 2014, 21:05:32
Collected my frame from the powder coaters today, as always they did a great job, they specialise in motorbike frames and wheels etc. For me its a half day return trip (traffic is always awful), but its worth the effort. I ended up with my little car full of other peoples parts on each trip, as when they knew I was going I was asked to take their stuff too.

Here's my frame being handed over at the powder coaters..
And a close up of the finish, I'll wrap it in foam / cardboard before trying to lift the engine in, I'd hate to scratch the finish..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: andycafe on Feb 28, 2014, 21:20:00
Very nice, I'm looking forward it coming together  ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Mar 01, 2014, 01:16:21
Clicked on
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: johnu on Mar 04, 2014, 14:50:35
Very nice work indeed!  This is the kind of build I love to follow.  Won't you need a crane to lift the engine in ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 05, 2014, 05:14:14
The engine is ridiculously heavy, but I decided not to wait for help to ease it into the frame, instead I wrapped the frame in card and foam, then placed the engine on its side on wooden blocks before dropping the frame carefully over it. Worked out ok, though took ages to fit all the mounting brackets and swing arm due to the thickness of the powder coat. Had to turn down the swing arm spacers a little in the end.

Also had a threaded 'bung' welded into the oil tank for the outlet fitting, saved having to cut a British Cycle thread to match the oil tank and since the bikes got a modern oil filter, there was no need to use the authentic Norton oil filter (just a crude wire mesh) that would normally sit inside the oil tank. We didn't finish tapping the inner thread in the bung for the oil fitting, as there was a small chance it would distort a bit when the bung was welded into the oil tank. Now that's done we can finish cutting the thread.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 08, 2014, 10:49:50
Got the oil tank fittings done and the oil tank bolted into the frame. For now I'm using rubber O rings to suspend the tank, not sure how they'll hold up in use, but only one way to find out..

When I came to order the chain, I didn't know how long it needed to be, so I ordered the longest DID in the book. Sure enough it needed a lot of links removing, which isn't a big deal. Then I came to fitting the Rivet link, I struggled to get the damn thing installed, cursing the new chain tool I'd bought specially. Till I noticed the rivet link had '520' stamped in minute writing on its side plate.. no wonder it wouldn't fit, as I'm using a 530 chain..doh! I'll get the correct link on Monday.

I'll also order a new front tyre, the 110 on it now looks a little too wide, so I'll replace it with a 100 Avon instead. This will make the 4 inch wide alloy mudguard work better too. Its just the blade I have, so need to make a mount for it yet.



Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Mar 08, 2014, 12:30:14
Hi, I read the entire build thus far and it's a beautiful bike and an interesting combination.  I loved the raw chromoly look.  My question is, why are the rear shocks cantilevered, outboard of the swingarm?  Great bike, should be a lot of fun to ride.
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Mar 08, 2014, 12:42:35
Hi, I read the entire build thus far and it's a beautiful bike and an interesting combination.  I loved the raw chromoly look.  My question is, why are the rear shocks cantilevered, outboard of the swingarm?  Mounted this way the bolt strength determines the rigidity of the shock mount.  Is it possible to mount the lower shock eye inside of the bracket.  Perhaps the rear portion of the swingarm could have been a bit wider?  Great bike, should be a lot of fun to ride.
  Cheers, 50gary
There is a steel sleeve that goes throughout the shock mount and through the shock eye so the sheer is on the tube and not wholly on the bolt. Stock Sportsters are set up this way also. I was going to say you can mount the master link on the bench but then realized with your frame the chain must be broken to get it off. Mine only requires removing a shock to get the chain off as a whole.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Mar 08, 2014, 13:03:29
beautiful really enjoying this
the oil tank  hangs on bungees?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 08, 2014, 14:28:23
beautiful really enjoying this
the oil tank  hangs on bungees?

The oil tank mounting caused some head scratching. The mounts at the top our obvious, but how to use the grooved bosses on the lower sides wasn't clear. Original Tritons used rubber loops to pull the oil tank down against the top of the gearbox, with a rubber pad sandwiched between to try absorb the vibes. On the Ace Café Norley they used the same method, but with the oil tank sat on a T piece welded to the rear engine mount. My frame didn't have this T piece, I did Email Norley to ask about this, but got no reply.

So before the frame went for powder coat I had a couple of hooks welded to the inside of the frame, to be used to hang the oil tank via rubber O rings, or some other suitable loop. I prefer my method as it better isolates the tank from engine vibes.

This is how the Ace Café Norley mounted their tank, notice the upright tube supporting the tank from beneath, which my frame doesn't have, and my bike pictured beneath
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 10, 2014, 17:50:49
Got a couple more jobs done today, finished the oil filter mount, uses the rear engine/gearbox mounting bolts, and made the rear light bracket in stainless plate.

Also started something I soon wished I hadn't.. the alloy petrol tank had a few light scratches, so decided it needed to be re-polished.. its going to take a lot of elbow grease ..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 14, 2014, 14:12:47
Collected the correct sized split link for the chain, and with my shiny new rivet tool the chain went on ok. Though I did have to pause half way through and go off to check on youtube the correct way of using the riveter, it wasn't obvious and it came without instructions.

Also changed the front Avon to a narrower 100 width tyre, the 110 looked good but the general consensus was that it will handle better with the 100. Luckily the 110 tyre fits my Guzzi Café racer so its not going to wasted. With the new tyre on, my next job is to work out how long I want the alloy front mudguard to be and how to mount it

I spent yesterday afternoon at Geoff the welders place, where he let me use his pipe belt sander, it saved me a huge amount of time linishing the welds of the stainless downpipes. They aren't perfect (I was afraid of sanding right through the pipe walls), and still need to be polished but overall I'm happy with the result.

I did hit one problem today, the oil filter mount (which I had been pleased with), just happens to place the oil pipes directly in line with the lower chain run.. should have thought of that beforehand  :( it'll have to be changed.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: teazer on Mar 14, 2014, 15:50:20
Really nice "Classic" look. That front pipe is quite a shape.  Front fender looks like it's designed to match a much larger diameter front tire though.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Mar 14, 2014, 15:53:05
Really nice "Classic" look. That front pipe is quite a shape.  Front fender looks like it's designed to match a much larger diameter front tire though.

Not mounted so the clocking makes it look weird, but you are right, probably for a 1" larger wheel.

Sucks that all your old build pics are dropping off the thread.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 14, 2014, 16:26:22
Really nice "Classic" look. That front pipe is quite a shape.  Front fender looks like it's designed to match a much larger diameter front tire though.

Ad said its made to fit an 18 or 19 inch tyre, once its cut down and mounted should be ok.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: johnu on Mar 14, 2014, 16:31:24
Looks great!  I would have probably just left the welds unsanded and polished right over them.

Is your chain a bit tight?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Mar 14, 2014, 17:13:45
Ad said its made to fit an 18 or 19 inch tyre, once its cut down and mounted should be ok.
You're running an 18" up front, correct?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Luugo86 on Mar 14, 2014, 17:36:56
that is a good looking machine
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 14, 2014, 17:55:52
You're running an 18" up front, correct?

yes 18 front and rear
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Mar 14, 2014, 17:58:25
yes 18 front and rear

I suppose the seller of the fender could have said it fits 16", 17", 18", 19". But it will only look right on a 19" due to it's corresponding radius. Cropping it will certainly help the wide end look.
Title: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: snowman on Mar 14, 2014, 20:23:30
I'm jealous, great work.....


Sent from my iPad using Tapatalk
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Mar 14, 2014, 21:14:31
I suppose the seller of the fender could have said it fits 16", 17", 18", 19". But it will only look right on a 19" due to it's corresponding radius. Cropping it will certainly help the wide end look.

LOL, if only ads read so well. ;)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Mar 14, 2014, 21:21:10

LOL, if only ads read so well. ;)

That's why I only listen to and believe about 1/4 of what anyone who is trying to sell something says. :D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DrJ on Mar 16, 2014, 10:12:35
Spotted this at an auction in Buffalo in 2009. Guy who bought it offered the motor to me for $600.

(https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/t1.0-9/5573_143385542673_176882_n.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Mar 16, 2014, 10:30:26
Cricky, he's got two featherbeds!   It just occurred to me that would be a good title for a magazine article, "Ironhead in a Featherbed" sub. "Opposites Do Attract"
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DrJ on Mar 16, 2014, 10:51:02
Those weren't the only two at that auction.

(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/t1/5573_143385282673_2233293_n.jpg)

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/5573_143385272673_4486808_n.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: focusinprogress on Mar 17, 2014, 10:09:35
^ I was at that auction too!!! I was only 23yrs old at the time and broke as a joke but I NEEDED to see the inventory. I bid on some parts lots but there were just too many people with deeper pockets than me.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 22, 2014, 12:38:03
Waiting on having the brake and clutch lines made, should be ready end of the week, so until then just been playing around with a couple of ideas. I wasn't happy with one area of the bike, so I took my trusty hacksaw and file and made this simple bracket, from a scrap piece of angled alloy plate. Spent an afternoon cutting, filing and measuring till it fit ok. But it didn't really look right, even if it was polished or painted or whatever, so I went off to drink tea and work on a MK2 version...   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 22, 2014, 12:44:49
I made a few test templates from cardboard until I came up with something that looked right, and with the brackets added this morning by Geoff the welder, just needs a little finishing and its done.. a 'Tiara' for the bike, to make the bright orange battery a little less obvious, and finish off the under seat area.. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: bluesmokey74 on Mar 22, 2014, 14:52:44
That "Tiara" is a nice finishing touch! Nice job! Love this build!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Mar 22, 2014, 15:44:49
(http://www.automizeit.com/blog/wp-content/uploads/2012/10/guinness-brilliant.jpeg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 1969Honda on Mar 23, 2014, 02:47:32
 8) 8) That's one "tiara" I wouldn't be ashamed to have on a bike! looks sweet
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 24, 2014, 14:07:27
Bought a sheet of neoprene to sit the battery on, and a roll of self adhesive neoprene foam for the seat rails.. gotta look after the powder coating. Don't know how well it well last, but I have a 10m roll so plenty left in reserve..

 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 24, 2014, 14:21:59
While I wait for the brake lines to arrive, and with the To-Do list getting shorter, I turned my attention to more arty stuff.. I want to engrave the points cover I made a few weeks ago. I haven't worked out just what to engrave on it, but spent an afternoon with a practice piece of alloy, playing about with a hammer and punch (far too slow) and my Dremal (much better.. but tricky to control).

The plan is to workout a simple design, that's not impossible for me to achieve, then mark it out on the points covers, before carefully grinding away the cover to leave the polished image/logo/whatever standing proud from the 'excavated' surroundings..

I did something similar awhile ago, when I took the broken pieces of an old Phosper Bronze shell bearing, melted them down in a homemade crucible using a blowtorch and then made a cast from a cuttlefish bone..  I polished and worked the result using my trusty Dremal into a pendant, which turned out pretty well..

Any ideas what to engrave on the points cover?
     
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Mar 24, 2014, 15:21:30
"place drip pan below"  ;D ;D ;D


love the bike, fantastic build
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 1969Honda on Mar 24, 2014, 15:51:36
Quote
Quote
"place drip pan below"
+1 LMFAO! Bike is looking killer!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: ProSimex on Mar 24, 2014, 19:46:00
This machine
KILLS
twin cams
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: buckeyebike on Mar 27, 2014, 09:05:12
Cool bike- that seat and new trim piece tucked under it is begging for a small cateye that doesn't protrude . . .
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 27, 2014, 13:27:56
Cool bike- that seat and new trim piece tucked under it is begging for a small cateye that doesn't protrude . . .

I've considered using an LED strip similar to a cateye, but prefer something more retro to match the style of the bike. Also the bracket it sits on would still be required to mount the number plate. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 30, 2014, 19:31:38
Think I'll go with this for the points cover, its just scratched on roughly for now on the back side of the cover, using engineers ink. I can try a practice run, and if it looks rubbish, no one will see it,

 
Title: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: neevo on Mar 30, 2014, 19:47:53
You need a pal with a CNC mill. That would look awesome in the cover either way.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 01, 2014, 13:25:42
I'm sure I could find somewhere to engrave / CNC the cover perfectly. But I'd rather have a go myself, if its cr*p, I can always make another cover or skim this one back smooth. Besides perfection is boring..

Anyway, made the logo a touch bigger, and used my Dremel to carve out the letters. It's not easy as the bit wants to wander about where you don't want it to go. I'll do more tomorrow, make it more 3D and as neat as I can manage..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: irk miller on Apr 01, 2014, 13:35:53
You could have just etched that.  It's a lot cleaner and much more neat.  It's a printmaking process.  You can use muriatic acid that can be bought at any hardware store.  Vinegar also works, but to a much less degree.  You paint asphaltum on any area you don't want the acid to etch. You can also paint the whole cover in asphaltum, then scratch through it with a scribe.  Chinese wax markers also work.  Lay the cover in a bath of muriatic acid and let it sit in solution for 5 - 10 minute increments until you get the bite you want.  The acid can be diluted with distilled water to lengthen the etching time and gain more control over the bite.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 01, 2014, 14:13:20
You could have just etched that.  It's a lot cleaner and much more neat.  It's a printmaking process.  You can use muriatic acid that can be bought at any hardware store.  Vinegar also works, but to a much less degree.  You paint asphaltum on any area you don't want the acid to etch. You can also paint the whole cover in asphaltum, then scratch through it with a scribe.  Chinese wax markers also work.  Lay the cover in a bath of muriatic acid and let it sit in solution for 5 - 10 minute increments until you get the bite you want.  The acid can be diluted with distilled water to lengthen the etching time and gain more control over the bite.

Interesting, I'd never heard of muriatic acid.. would Caustic soda in solution do the same job? Something to consider another day. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Apr 01, 2014, 14:35:07
FANTASTIC !!  :D
yes you could have gotten a very precise image with etching and the process is not all that difficult
personally i like moar better what you did there, it is true hand made art one of a kind


Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: irk miller on Apr 01, 2014, 15:01:17
Interesting, I'd never heard of muriatic acid.. would Caustic soda in solution do the same job? Something to consider another day.
  No, you need an acid.  Caustic soda, which is sodium hydroxide or lye, is a base.  Muriatic acid is hydrochloric acid.  You can also use what's called sodium sulfate etch which is a recipe of 1 copper sulfate to 2 salt by weight.  Copper sulfate is the by-product of breaking down copper with sulfuric acid.  For example 70 g of copper sulfate, 140 g of salt mixed into 1L of water. 

BTW- I say this not to be critical of you handwork.  Handmade has it's own inherent beauty.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 01, 2014, 15:07:53
Yes, I wanted it to look hand made. I did consider casting a cover from melting down old phosphor bronze shell bearings, then carving out an image.. gives a very warm gold like colour. Did it once before, only found out afterwards that phosphor bronze has a very high melting point.. explains why it was hard to melt lol..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 01, 2014, 15:25:25
Chemistry has never been my strong point, despite spending most of my career in the chemical industry..

Well, bit off topic, but this is how the Phosphor Bronze casting looked after some work, looks like gold and almost as heavy, though it tarnishes after awhile..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 02, 2014, 13:24:25
Here it is on the engine, hopefully the rough alloy surround will dull down in time..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: BarnBurner on Apr 02, 2014, 16:26:25
I like it. At 5-10 ft it probably looks great. Any closer and you can appreciate the fact that it was handmade, just like the rest of the awesome details on this bike  :D
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: WeberKid on Apr 02, 2014, 21:48:08
I'd give it a really quick dusting in a sandblaster and polish the text.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 09, 2014, 23:00:15
My self imposed deadline for finishing the bike has been and gone, and its not running yet. But since I set the deadline, I took a management decision and moved it. Actually the main reason is that I'm doing far more of the work than I expected, and I'm learning as I go along.

I finally settled on the type of oil line to use.. braided steel and those lovely blue and red anodised fittings would usually be my default choice, but that was too modern, while simple black nitrile hosing seemed a little too plain and low rent. So I went for over braided nitrile tubing with stainless clamps.

The oil filter mount placed the oil lines too close the chain for comfort, so it was modified to angle the lines down to clear the chain. Its a bodge for now, using a short bracket with the original billet mounting plate, its something I'll revisit another time, at least I had my detailed technical drawing to guide me  :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 09, 2014, 23:12:03
I found these neat mini waterproof switches, which I'll use for the horn and hi/low beam, just managed to fit them next to the ignition switch, which will keep the wiring out of sight.

Hit a couple of small problems along the way, damaged case threads and I cant remove the old broken oil pressure switch to fit a replacement. Its in a tight spot and the nut has been rounded off some time in the past and it doesn't want to come off. I should've removed it before the motor was back in the frame, but I didn't want to risk damaging the new pressure switch when fitting the engine. I may have to remove the oil pump, which could open another can of worms..we'll see.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SONIC. on Apr 10, 2014, 01:27:22
I found these neat mini waterproof switches, which I'll use for the horn and hi/low beam, just managed to fit them next to the ignition switch, which will keep the wiring out of sight.

Hit a couple of small problems along the way, damaged case threads and I cant remove the old broken oil pressure switch to fit a replacement. Its in a tight spot and the nut has been rounded off some time in the past and it doesn't want to come off. I should've removed it before the motor was back in the frame, but I didn't want to risk damaging the new pressure switch when fitting the engine. I may have to remove the oil pump, which could open another can of worms..we'll see.

Looks like a pair of needle nose vice grips would get that right off, or am I missing something?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Apr 11, 2014, 18:45:47
My .02  I love the bike but the horn switch placement makes no sense whatsoever. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 11, 2014, 19:19:39
My .02  I love the bike but the horn switch placement makes no sense whatsoever.

When did you last use the horn on your bike? I cant remember ever using mine, if someone cant hear the open exhaust, they certainly wont hear the beep beep of a typical bike horn. So it make sense for me, as I'll never use it and it keeps the wiring hidden. If it wasn't a legal requirement, I wouldn't have one.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Apr 11, 2014, 19:25:04
I don't run open pipes but I've definitely used my horn to alert blind idiot cagers that I don't like them running me over.  I've bought a Stebel horn as a replacement for the weak ass stock beeper.  The Stebel horn will cause an inattentive driver to leave a brown stain on their seat. 


After I noted your placement I did assume it was for legal reasons.  No worries, keep up the great work on that beauty. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 12, 2014, 16:41:30
I don't usually bother with bike electrics, making up a wiring harness etc, I leave that to my local bike shop. But this time I thought I'd give it a go and see how far I got. Made a start with replacing the points with electronic ignition. The instructions were a little confusing, as they referred mainly to big twin Harleys, and different years needed different approaches. There was even a small packet that said 'DO NOT USE!'.. which in the end I did lol..

Start by removing the points, then the backing plate and finally the advance/retard unit, all pretty straight forward. Then I had to put the bike in gear (not so easy without the clutch working), and find TDC on the front cylinder. This done, I could fit the rotor to the end of the crank, not sure why I had to find TDC, as the rotor can only fit in one way, but hey ho, best follow instructions. 

Next had to measure the cap between the rotor and the back of the plate that holds the ignition module. If its more than 0.075 of an inch, I had to use the spacer in the 'DO NOT USE!' packet.. it was so I did. Finally loosely fit the ignition module, lining up a V notch in its plate with a similar notch cast into the engine case. There were 3 notches in the case, so I lined it up with the middle one. The final timing will have to be set with a timing light, but hopefully its close enough to get the motor to run.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 14, 2014, 20:37:24
Was a sunny spring day here in ye olde England, so made the most of the fine weather by taking the 888 for a blast. Then spent the rest of the day fettling the Ironhead.. oil lines done just need a couple of zip ties to tidy things up beneath the engine. That allowed me to fit the sprocket cover (Left it undrilled for now), and the exhaust which needed a some last minute work to give more clearance from the frame tubes. The front pipe is still close to the down tubes, but should be ok.

Still being held up waiting for the promised brake lines, but getting them at mates rates so shouldn't really complain.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Apr 15, 2014, 13:08:47
Beautiful!   8)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DesertKZ on Apr 15, 2014, 14:16:03
Awesome!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Apr 15, 2014, 14:31:31
stunning !
can we get some video, full song on  fly by ?  :) 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: M.B Co on Apr 15, 2014, 17:27:06
I foresee a Bikeexif, pipeburn, returnofthecaferacer, thebikeshed.cc feature. Build is simply epic.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 15, 2014, 19:02:36
Been struggling trying to work out a wiring diagram for it, I hate electrics. Made a start and bought myself a soldering iron and a few metres of wire. When finished, I'll try to film it being run up on my mates dyno when I take it to get the carb jetting /ignition timing right. If I can borrow a Go Pro type camera, I'll take some 'on board' film too. Not sure about those other websites, I'm building it for me, not to advertise it on some website.     
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: downtown809 on Apr 15, 2014, 23:59:05
Yes, like, thumbs up, inspirational...
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on Apr 16, 2014, 12:38:30
Been struggling trying to work out a wiring diagram for it, I hate electrics. Made a start and bought myself a soldering iron and a few metres of wire. When finished, I'll try to film it being run up on my mates dyno when I take it to get the carb jetting /ignition timing right. If I can borrow a Go Pro type camera, I'll take some 'on board' film too. Not sure about those other websites, I'm building it for me, not to advertise it on some website.   


Instead of soldering your connections, I would highly recommend using these kits instead:
http://vintageconnections.com/


The CK2 kit comes with a very well made crimp tool that you will get tons of use out of.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 16, 2014, 16:59:32
I'll be using connectors, in fact just spent a small fortune on wiring, heat shrink, relays etc, should be here beginning of next week. 

Well, I don't have a vid of it running yet, but I took this short video this evening..

http://youtu.be/SE-o0zMiv7E
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: M.B Co on Apr 16, 2014, 18:05:43
Heat shrink terminals are the best thing ever.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 29, 2014, 15:19:04
Almost completed the wiring, in the past I would have run a mile from attempting to wire a bike from scratch, but having spent the time to understand relays, circuit breaker etc, its not so bad after all. Ideally, I wanted all the electrical components to be hidden away in one place, but there just wasn't the room. So I had to split things up into three locations.. in the headlamp shell, on the side of the top motor mount (under the tank), and in a tiny tray behind the oil tank (still waiting for that to be made in stainless). 

Before I did anything on the bike, I drew out the wiring on paper, splitting the job up into simpler diagrams, one for the ignition, one for the charging circuit, one for the starting circuit and so on. That done (it took a few versions before it all looked ok), I worked out where everything could be squeezed on the bike, after which it was just a question of being neat and tidy with the wiring and running the wires on the left hand side of the bike if possible (the least visible side when its on its side stand). I used 6 gauge wire for the main earth and starter cable, probably a bit too big, 8 gauge would've been more than sufficient, but it will help all those electrons get to where they need to go. 

Got a problem finishing the digital instrument wiring, as the installation instructions that came with the tacho were wrong, and don't want to risk damaging it by testing out each wire. Waiting to get the correct diagram emailed from the seller this week.

Also got the front brake lines done at last, need to make a pair of brackets to tie them to the fork legs and something better than a zip tie to keep them neat.  I've been testing and testing and retesting the wiring as I go along, and so far I'm surprised it all works.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on May 08, 2014, 11:04:56
Got the stainless mini electrics tray, drilled it to mount the relays and main circuit breaker, fits ok, and todays lesson : don't check for burrs with your finger.. ouch :-[

Also re jetted the carb with the mains and intermediate jets recommended for the engine with a free flowing exhaust. Luckily the Super E comes with a good selection of jets from the factory, including those I needed. It only took 5 minutes to change them, bit quicker than the same job on an inline four.

That done, I gave in to temptation and sprayed some petrol down the carb and pressed the starter.. it fired up for a few seconds which was a big relief. Got to sort out the instruments wiring and their sensors now I've been sent the correct wring diagrams, and make up the clutch line and (assuming the hydraulic clutch conversion actually works) it should be ready for the road at last. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: canyoncarver on May 08, 2014, 13:57:49
on your pic of the carb, don't miss the small o ring that goes here: 

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on May 08, 2014, 18:00:27
Well spotted.. Its a new carb, never opened it up before, so hope that O ring is there somewhere..
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: K0Kid on May 17, 2014, 10:35:39
The oil tank mounting caused some head scratching. The mounts at the top our obvious, but how to use the grooved bosses on the lower sides wasn't clear. Original Tritons used rubber loops to pull the oil tank down against the top of the gearbox, with a rubber pad sandwiched between to try absorb the vibes. On the Ace Café Norley they used the same method, but with the oil tank sat on a T piece welded to the rear engine mount. My frame didn't have this T piece, I did Email Norley to ask about this, but got no reply.

So before the frame went for powder coat I had a couple of hooks welded to the inside of the frame, to be used to hang the oil tank via rubber O rings, or some other suitable loop. I prefer my method as it better isolates the tank from engine vibes.

This is how the Ace Café Norley mounted their tank, notice the upright tube supporting the tank from beneath, which my frame doesn't have, and my bike pictured beneath

   Let me make an observation about the oil tank for a future revision. My oil bag (stock steel tank) on my Triumph 650 would tear the tabs off the tank and open a hole on the back side even though the tank was suspended from 2 straps with tubes at the end and 2 isolastic rubber bushes. The oil tank was so heavy that over time the mounting tabs just couldn't carry the load even with a supporting L(90 degree) bracket at bottom of tank also rubber bushed, we all know there was concern for vibration especially in a Triumph. A good engineering practice is the support the weight of the tank on something solid. It seems the way Norley did it is one way but it does illustrate the notion the tank should sit on something. A single post or tube would make me think eventually the weight will punch a hole in the bottom of the tank.

 A better way might be to let tank rest against the small diameter cross tube you have on your frame about 2" above the swing axle. I notice so far you are not running a rear fender or a flat panel just ahead of the tire. Instead you have created a curve in the tank itself that I'm sure you matched to the radius of the tire. But similar to the issue with the radius of the front fender the radius of the rear tire although it may be the same as the tire doesn't ever match the radius ( not concentric ) of the tank except at one finite point of the swing of the axle and becasue it is so short draws attention to itself. This is visually competitive. The way you have mounted the top of the tank with an addditional tab (horizontal or some angle ) that will tend to change as tank pulls the tab downward at an angle again visually too busy, if the tab on the frame was bigger and tank thru bolted thru side of tank using your bung feature it would still support the tank (a straight downward hanging load even if the bolt loosened at the top it would still carry the load but the way it is now the tank wants to rotate into the rear wheel with the tanks rear bottom edge coming into contact with tire.

Also your use of the orings aren't really doing their job. My suggestion is to make a thinner, longer tank maybe wider tank that would fit againts the rear of frame to act as fender shield. Although for safety reasons and cleanliness (you will ride in the rain over there, no? I would run a shaped or flat plate to protect oil tank from rocks kicked up by tire and as an innner fender against water. Most Jap bikes have a plastic liner here and use a separate fender above the wheel.  I know the cafe look is to throw all this crap away but without a liner you will be cleaning the crap off your oil bag all the time. Making a different shape to the oil tank will do 2 things open up the visual space between the rear cylinder and head and allow easier mounting perch for the oil bag. Currently it looks crowded with tank up against engine and /or hanging out in mid air not to mention its trapezoidal flowing shape. A simpler tank more rectangiular like a flat box of tissues, longer, wider and only 2.5 inches thick, you could still radius the back side but the longer it is, the less curious it will look.

 Now finally the piece d'resistance the proper use of the o-rings as rubber bands. The current tabs will tend to cut the o-rings. See attached Norton solution or aftermarket Norton race solution on a revised Norton, simple and elegant. Love your circular bungs at side of tank and with the orings doubled over but around the lower crossover tube just above the swing arm which would hold tank firmly against that tube with a thin strip of rubber in between as anti chafe to anchor tank against frame at bottom and load of tank carried above thru the 2 lugs and tabs on the frame.

An alternative is to use small angle iron as a cup on the same lower crossover rail so the tank rests on it carrrying all the load but also anchored to it by the o-rings.  Otherwise Bevelhead, a masterful project so far.
PS
 I recieved my Cali II Guzzi from snow country and have a line on the bottom Tonti frame tubes for the conversion, can't wait to see this finished and a restart on your Guzzi project. The race is on !
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on May 17, 2014, 13:31:18
The oil tank, there is nowhere to rest it upon, unless I strip the bike down and modify the rear engine mount cross member.. which I don't want to do. Also the trad Triton method of holding the oil tank down against the top of the gearbox will transfer more vibration with or without a rubber mat between the two. If I followed that route, what happens when or if one of the rubber straps fails? With my method its a ten second job to replace it, with the trad method, I'd have to remove the rear engine mount, not a quick or easy task.

I do have a 5inch alloy rear mudguard that I may or may not use on the bike, haven't decided yet. If not, I'll still fit some kind of splash guard to protect the back of the alloy oil tank. Its position in the frame is governed by the need to clear the rear exhaust, and the rear tyre at full compression. Its positioned now so that the top surface is parallel to the top frame rails. But again if needed its easy enough to change.

The curve of the rear tyre isn't concentric with the back curve of the oil tank, but I think it still looks better than the original Norley oil tank which was a big angular affair, as seen on the Café racer TV series awhile ago.

Besides most of the photos I've posted have been at knee height, as that looks better, but in reality this is how you'll view the bike, so the rear of the oil tank wont be such an issue if I leave it as is. 
 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: K0Kid on May 18, 2014, 23:21:16
Bevelheadmhr,
Short of resting it ON something, I'm saying rest it AGAINST the lower frame tube which is just above the swing arm axle tube so the frame doesn't need to modded but hang it at the top of the tank in the center of the top so its balanced. I agree resting it on the eng. or trans will impart much vibration, so I'm saying to isolate it from the frame. At the top it could be rubber bushed with a lug each side on the frame with a rubber bush so bolt shank hangs in bush(instead of a tab and bolt ) carries whole load and at the bottom just a sliver of rubber where it rests against the x-wise frame tube. Loosen bolts at top use rubber orings to set angle then tighten top bolts. Then its rubber bushed,isolated, no vibration, no torque on mounts and Norton pic says it all. Will oil tank be polished (draws too much attention) or painted (more of a whole, part of the basic chassis?
endeavour to persevere,
OMO
Ross
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 01, 2014, 00:03:14
Quick update.. The brake lines and clutch line have been fitted and bled, and all seemed well. My homemade hydraulic clutch conversion felt ok, not that light but usable and I was just happy it worked at all. But soon after the lever went back to the bars.. oh oh, somethings gone wrong.. sure enough the slave piston seal had failed. Not a big surprise, as I had been in two minds about replacing the seal as its came off a twenty year old Ducati Monster. I took the chance it would be ok. Hey ho, got to find an aftermarket seal now. Google suggests a 'Quad ring' O ring design will work better than the OE part. A job for next week. I'm also waiting to hear if the faulty speedo will be replaced foc, fingers crossed it will as it wasn't cheap.

So to cheer myself up, I got a bigger Eaton M112 blower to replace the M90 I already had for another project  :)

   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: MickyC on Jun 01, 2014, 01:01:26
I have to be honest mate I thought painting the frame black would not look as cool as clearing over that beautiful bronze welding but I have to tell you she came out a beauty. well done. subscribed
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 01, 2014, 14:54:21
I did ponder having the frame clear coated for a long time, but I'm happy I went for gloss black in the end. Well, the hydraulic clutch troubles continue. I removed the home made slave cylinder expecting to find it leaking fluid into the Primary case. But surprisingly it was bone dry, no hint of a leak. So I reattached the line and bled it again, off the bike so I could see what was going on. The slave piston moved out as it should when the clutch lever was pulled, but I was then able to push it back in with my thumb. Which shouldn't happen, so the fault lies at the second hand master cylinder not the slave. Its good really, as it means my home made slave cylinder is ok, now need to buy a rebuild kit for the master cylinder. Its from a Honda VTR1000/VFR800 so should be easy to find.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: TriBSA Chas on Jun 02, 2014, 05:26:50
I'm interested in making a hydraulic slave cylinder for my TriBSA. I have a lathe but I'm unsure how to go about the job, how did you get a smooth surface for the bore of the cylinder and what clearance do you need between the cylinder and bore?

BTW are you in the UK? I'm based in Cheltenham.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 02, 2014, 14:25:20
Ref the slave cylinder.. The bore was machined on a lathe, we just copied the diameter of the Brembo slave cylinder I got from a Ducati. Don't have the exact clearance as my mate did the machining while I drank tea and ate all his biscuits lol.  Its a smooth as we could manage, he didn't do anything extra than just machining the bore. Looking at the original OE Brembo, its bore isn't glassy smooth, so I guess the seal can deal with any tiny imperfections. The difficult part of making the slave was cutting the big imperial thread to match the primary cover. Couldn't do that so handed over to a local friendly machine shop who did for me for a tenner.

So my advice would be to buy a matching clutch master cylinder/lever and slave from a popular bike (parts easy to get) and either make the original slave cylinder fit the engine (seen this done on Big Twin Evo Harleys), or replicate its dimensions if you decide to make your own. Another option is to keep the original release mechanism but activate it via an hydraulic ram, again seen this done on Suzuki GS1000 and Harley Sportsters (Magura make a kit to do this).

Yes, I'm in the UK, in Cheshire.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: brad black on Jun 03, 2014, 08:26:15
i've seen a few aftermarket pistons with 2 or 3 o-rings, which keeps the piston off the bore.  just need to keep them all lubed.

if you spin the lathe fast and take some light final cuts you should get a nice smooth finish for the bore.  i usually linish those early ducati slaves with scotchbrite when i want to clean them out, and it will give a nice finish to an already smooth surface.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 19, 2014, 14:07:39
Been away for awhile, but when I got home the rebuild kit for the clutch master cylinder had arrived, rebuilt it ok but now its proving a pain to bleed, ditto the rear brake. I'll leave it overnight see if it helps.

A bolt which used to hold the foot peg in place by passing through the primary chain case served no purpose, now its got rearsets. So I replaced it with a alloy bung, its slightly tapered, and after a few hours in the freezer, it went in with a few gentle taps. Hopefully it'll stay there..and another 102gms in weight saved!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Hoosier Daddy on Jun 21, 2014, 07:25:13
Constantly in awe of your craftsmanship.
Do you have a hand vacuum pump to assist in bleeding the hydraulics?
 
(http://www.fjrtech.net/images/controls/clutchfluid/mityvac_photo.jpg)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 21, 2014, 10:51:36
No, but I was so fed up, I ordered a vacuum kit a few days ago and it arrived today, will give it a try later.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 21, 2014, 15:17:30
And here it is..

Worked ok, except the clear tubing was too big for a bike's bleed nipple (no doubt made to fit a car). Fixed it by pushing a smaller tube inside it and using that. I now have a working front brake and clutch. The clutch pull is suspiciously light, but seems to work ok.

The last task was to bleed the rear brake, soon found that like the second hand clutch master cylinder, the rear brake master was leaking under pressure. One step forward, one step back. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: xb33bsa on Jun 21, 2014, 15:44:49
just sayin, but if you can't bleed brakes(that have good condition components) very easily without a vaccum pump you are doing SOMETHING wrong
and it is almost always an improperly bled master
keep up the good work and reporting
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: kiwi60 on Jun 21, 2014, 16:37:36
Brake bleeding can be a real pain in the a$$ sometime, for no good apparent reason.


I’ve come up against the same problem, and came up with the following method for a quick; cost effective way to get them sorted.

Let me just say that bleeding brakes is not one of my favourite jobs and over the years I've invested in a ‘brand name’ brake bleeder which never really worked right, or used the monotonous pump / open bleed nipple / close brake nipple / pump etc etc etc

However I discovered an extremely quick, effective way to bleed the brakes, and guarantee that there are no air bubbles in the lines.

First, get a new bottle of brake fluid, and – here’s the important component - a length of clear tubing that’s a nice snug fit over the bleed nipple and long enough to easily reach the master
cylinder.

Right then, take the top off the brake reservoir, open your nice new bottle of brake fluid and fit one end of the tube over the nipple. Next, thread the remaining tube up to the handle bars with the end near the reservoir (a cable tie to hold it to the upper fairing stay / mirror works a treat.
Start bleeding the brakes in the normal way - a few strokes on the lever then a slow stroke as you crack the nipple open a bit to let the air through. After there's about 150mm of brake fluid in the tube, I didn't have to keep opening and closing the nipple any more.

Carry on pumping the fluid until it’s is almost to the top of the clear tube (being careful not to let the reservoir pump dry), and then a few more pumps of the lever to get the fluid to the end of the hose and then put the end of the hose into the top of the open reservoir, making sure the tube can’t slip back out.

What you now have is continuous bleeding as air cannot enter the tube because it’s under the surface if the fluid level.
You can now crack open the bleed nipple and pump away for several minutes - you'll be surprised how long the small air bubbles take to get all out.
I did this on both sides with a 100% drained front brake system and had them fully bled in 17 minutes - usually I'm swearing at it for at least an hour or so.

Just one note of caution - make sure everything is completely clean with a few well-placed rags to catch and fluid spills.

And the cost of the hose - about $1.50.

(http://i63.photobucket.com/albums/h135/kiwi60/0032_zps411926e5.jpg) (http://s63.photobucket.com/user/kiwi60/media/0032_zps411926e5.jpg.html)

As you can see, it works well even if the caliper has two bleed nipples  :)

Hope this can help someone save some time and frustration.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 29, 2014, 20:44:57
The bike now has a new rear master cylinder, and a rebuild the clutch m/c (seems everything I bought second hand was worn out lol). I now have a working clutch, smooth but far too heavy. So what's required is a smaller master cylinder or a bigger slave cylinder. The latter was cheapest, so I bought a second hand slave from a Honda VTR Firestorm. Need to make a new mount to fit it to the bike, one where I don't need to mod the slave cylinder itself.

Also saved a whole 100gms by replacing the hefty obsolete foot peg bolt that fits though the primary with a little alloy plug. It spend the night in the freezer before being tapped into place. Hopefully it'll stay there.

It still needs to go on the dyno to set up the ignition timing and jetting, but that will have to wait a few months when my mates dyno shop isn't so busy, and so it can be done for free.

I've already started another project (must be mad).. another HD but something a bit faster this time..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 05, 2014, 14:58:02
Last update for this year anyway, a couple more pics, taken at a ring of standing stones near me.. I await jokes about ancient monoliths... :)

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Aug 05, 2014, 16:20:06
Sweet build. What are your plans for a fork brace/fender? The only thing wrong with that bike is the pipes come out of the motor on the wrong side and only one carb. ;) Excellent workmanship.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 05, 2014, 16:34:32
I've got an alloy front fender, that's not fitted in the photos, as it doesn't look quiet right.. bit too narrow. The forks are 43mm in thick billet yokes, they don't really need a brace on such a light bike, though I'll probably make one if I don't fit a front guard soon.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Aug 05, 2014, 17:07:00
Did you get a final weight on it
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 06, 2014, 13:06:05
Did you get a final weight on it

189kg with about 10 litres of petrol in the tank.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Aug 06, 2014, 18:21:59
That's quite a good weight with that engine!
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DrJ on Aug 08, 2014, 00:49:26
I don't care what the purists say, the Ironhead motor looks best in that frame. My vote for DTT bike of the year.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DesertKZ on Aug 08, 2014, 16:09:50
I don't care what the purists say, the Ironhead motor looks best in that frame. My vote for DTT bike of the year.

I have to concur, so much detail in there.   :)
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: mechdesign2k4 on Aug 21, 2014, 12:52:39
dead sexy
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: coyote13 on Aug 21, 2014, 13:22:14
100% aqgree on BOTY.  I do love a good sportster, and this is one of the best I've seen come to fruition.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Aug 21, 2014, 22:20:42
I saw your bike on "Inazuma Cafe Racer"  Looks great there too.  I also must say, I concur with the Iron Head in the Featherbed looks very comfy, it belongs there.
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 24, 2014, 05:20:42
A quick update on how its going..

I haven't had chance to ride it hard yet, and it still needs to go on the dyno to tune the jetting and ignition. But first impressions are

1) It handles well, feels light and agile (glad I swapped to a narrower front tyre), lots of ground clearance. Reminds me of my old 78 Ducati 900ss Desmo, but with slightly quicker steering. Its stable too, no head shakes while cornering on bumpy roads.

2) Riding position is ok, the clip ons aren't as uncomfortable as I'd feared look, though I don't plan on touring on it. I'll need a break after a couple of hours.

3) The suspension is 'unbalanced', in that the forks are firm, perhaps a touch too firm, while the rear shocks are well damped, but the springs are too soft. I'll probably fit firmer and 1 inch longer rear shocks, I'll get a pair custom made for me by Maxton when I can afford it. They build the shocks to suite your own riding style, weight etc.
http://www.maxtonsuspension.co.uk/files/home.htm

4) Its pretty loud, sounds great, but don't think my neighbours will be too impressed. The reverse cone Megaphones are called 'Bofors' for good reason.

5) The alloy tank marks easily, its going to be a never ending job to keep it polished and looking good. A painted tank would've been easier to live with, something I may consider later.

6) Engine feels like it has enough power to be fun, the 4 speed gearbox is a bit clunky, and there's a big gap in ratios between 2nd and third gear. Need to get used to it I guess. I'd always planned to tune the motor once the bike was on the road and debugged. But now I may not bother, other than making a pair of alloy barrels someday.

Overall, I'm pretty happy with how it turned out. It took longer to build than I had expected, partly due to being on a tight budget and partly because I wanted to do as much as possible myself, rather than farming the tricky work out to the experts as I'd usually do.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: irk miller on Aug 24, 2014, 09:57:28
You might want to consider Sharkhide for the polished aluminum:  http://www.sharkhide.com (http://www.sharkhide.com).
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: CrabsAndCylinders on Sep 08, 2014, 13:18:20
This is one beautiful bike, congrats!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: rundown on Sep 08, 2014, 17:46:49
Ditto on that beautiful bike comment.  Not sure why those Harley engines look so right in an English frame, but it is a marriage that obviously works beautifully.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: panelrodder on Dec 15, 2014, 17:41:52
Nice build!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: AgentX on Dec 17, 2014, 03:36:17
Have you considered trying Shark Hide on the tank?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Dec 17, 2014, 11:22:41
Have you considered trying Shark Hide on the tank?

No, as its not easily available in the UK. The bike's now tucked up in the garage until spring, sprayed plenty of anti corrosion FS365 on it to protect it from the damp. When my new project is finished, I'll do some more updates on the Norley. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 06, 2015, 21:08:06
Apologies for bringing this old thread back to life, its because when I was bored stuck indoors being ill recently, I put together a step by step build video of my Norley, a lot of the photos I've posted here, its about ten minutes long, let me know what you think.. be kind, its my first attempt ..

https://youtu.be/dn-VGHidxzs

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Apr 06, 2015, 22:51:37
Very nice slide show, good job all around.  I may have mentioned this before but the Net weight is quite impressive 415#  and for using that HD motor it's really light weight.
 Cheers, 50gary
 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Apr 07, 2015, 19:31:31
Very nice slide show, good job all around.  I may have mentioned this before but the Net weight is quite impressive 415#  and using that HD motor it's really light weight.
 Cheers, 50gary
 

The Ironhead engine is around 188lbs, which is pretty hefty for an air cooled V twin. A later Evo sportster version is 10lbs or so  lighter, using one of them and modern lightweight 17 inch wheels would get a Norley down below 400lbs no problem.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: o1marc on Apr 07, 2015, 19:39:53
The Ironhead engine is around 188lbs, which is pretty hefty for an air cooled V twin. A later Evo sportster version is 10lbs or so  lighter, using one of them and modern lightweight 17 inch wheels would get a Norley down below 400lbs no problem.
That is the correct weight number I came up with, actually  I didn't come up with it, it's in the manual. I was able to take 50lbs off my motor. Aluminum cylinders and heads are are right at half the weight of the iron ones (12lbs/13lbs, aluminum ones are 6 and 6.5), tossed the generator regulator for another 13+lbs, light flywheels drop some more, no kickstart hardware at all.
That 188lb number is for the IronHead XLCH, the XL and XLH models were 204lbs. The latter is most likely what you would be working with. My bike weighs in a 332lbs dry.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 04, 2015, 13:16:08
They say custom bikes are never really finished, as there's always something that could be improved or changed in the light of riding the thing. So it is with my Norley. Before I start on my next big project I want to fix a couple of issues, the main one being the heavy clutch.

The clutch activation is a one off hydraulic system, using a master cylinder from a Honda VTR1000 and slave cylinder from a Ducati 900 Monster, with a custom billet housing. When we made it, I knew it was an experiment and there was a good chance the ratio of Master to Slave wouldn't be perfect when used on an old Harley engine. Sure enough it turned out to be very heavy, too heavy for me, particularly if I was ever caught in slow moving traffic for more than a short time. Also the bleed nipple was part of the banjo bolt fitting, which made bleeding the system very difficult, unless I could somehow tip the bike on its side, which I couldn't.

Time to make a Mark 2 version..

The Ducati Slave is 26mm in diameter, so to make an lighter clutch, it would need to be replaced with a bigger diameter slave. How much bigger ? No idea !  So I went with a Honda 36mm Slave cylinder to match the Honda master. For this Mark 2 version I wanted to avoid making a completely unique slave body, because if it failed/wore it would be a lot of work to make a new one. Much better if I could use the standard Honda part and just make some kind of adaptor to fit it to the Harley.

So that's what we're doing, the adaptor is on the large size, now I've just done a test fit for the first time, so when I take it back to Jeff's workshop I'll try to shape it to match the profile of the slave cylinder, which should hopefully make it a look a little better.     
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Dale on Jul 06, 2015, 12:44:44
Just watched your vid. :-) Really cool seeing it all come together like that. Beautiful machine you've turned out over there.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 13, 2015, 17:52:05
Done a bit more work on the new slave cylinder, took some weight of it and made a bronze sleeve to help keep the new longer pushrod aligned. It should be fitted, bled and tested by now, but unfortunately I put my back out the other day.. incredibly painful, so no more bending down working on or riding bikes for me for a week or two  :(
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: john83 on Jul 15, 2015, 00:26:17
Sorry to hear about the back, hope you get well soon. It's been really cool watching this whole thing come together. It's a great looking bike! I believe we need a video with some engine sound though!
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 17, 2015, 15:09:48
The intention was to borrow a Go Pro or similar and make a short video on the move, but haven't found anyone who has one yet, next plan was to film it on the dyno, which in turn hasn't happened yet.

Well, at least my Mark 2 slave is almost done, shaped the mount to match the Honda slave cylinder and lose some weight. Unfortunately the angled fitment on the existing hose wont fit the new banjo bolt location, so I've had to order a new hose for the clutch. I just hope it works after all this effort !

 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 24, 2015, 17:12:59
The new clutch line arrived today, so once fitted I spent ages bleeding the system until the lever firmed up and it all seems to work well. The lever effort is now much lighter as expected, while there is enough movement in the slave cylinder to disengage the clutch. It'll be awhile before I can try it out on the road, but I'm happy with the change so far.

   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Sep 08, 2015, 20:35:48
The next job to do on the Norley is to finally mount the front alloy mudguard. My first attempt, using an alloy fork brace didn't work, so this time I'm making it in stainless steel, similar to the Ultimate Source fork braces that were popular on BMWs back in the 80's.

The Honda forks on the bike don't make things easy, as their fender mounts are offset both vertically and horizontally.

I took two pieces of 5mm stainless rod to Jeff the welder, where he let me use his rollers (a giant mangle looking thing) to curve the rods to follow the profile of the alloy fender. Each pass through the rollers curved the rod a little more. That done, Jeff welded on a pair of mounting tabs to each rod, which I'll use to bolt the fender to the underside. I need to take careful measurements before these rods are cut down to the correct length.

Next I used a couple of off cuts of 3mm stainless plate which need to be drilled and shaped to bolt to the inside of the fork sliders, which the curved rods will then be welded to. Before I can go any further with that tedious job, I needed a couple of 12mm spacers which makeup for the offset in the fork mounts..

That's as far as I've got so far..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: grandpaul on Sep 09, 2015, 11:22:19
Last update for this year anyway, a couple more pics
(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54062.0;attach=124713;image)

This has to be the nicest looking Feather-Davidson I've ever seen.

Well done.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: SF on Aug 30, 2016, 13:18:27
How did ya make out with the mud guard mod? hope the back still isn't an issue............
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: grandpaul on Aug 30, 2016, 18:43:40
Triton frames are almost always nickle plated.
I don't think so, Tim...

Going back the first ones, in the 50s, there are probably 59% black, 20% silver, 10% red, 10% chrome/nickle, and 1% other colors.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: grandpaul on Aug 30, 2016, 19:06:19
Best Featherbed HD I've seen built, after looking closely. Some really nice work and well documented.

I wonder how the intervening year went for this bike?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 31, 2016, 00:48:48
Best Featherbed HD I've seen built, after looking closely. Some really nice work and well documented.

I wonder how the intervening year went for this bike?

Its still in my garage, still got a few updates I want to make, and its still a keeper.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 31, 2016, 00:53:15
How did ya make out with the mud guard mod? hope the back still isn't an issue............

I didn't like the mudguard when it was on the bike, its too narrow, and not yet found a wider, more suitable alloy guard to replace it. Think I'll end up having a one off made someday. My back is ok, about 95% better, which means I 'm riding again which is what matters. 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: hooligan998 on Aug 31, 2016, 01:03:02
I'm late to this party, but I'm in.  Love this build.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Aug 31, 2016, 02:46:04
I'd like to build a second engine for it, but with alloy barrels and other go faster stuff, but it seems all the old Ironheads have been snapped up by the hipsters who have pushed prices way high. Oh well, always other projects to play with..

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jan 02, 2018, 07:26:10
One of my new year resolutions is to update my Norley, sort out a few problems and improve it here and there. Since I built it, I haven't used it much, and its spend most of its time sitting forlorn in the corner of my cold damp garage, which hasn't done the polished alloy much good.

So a few weeks ago I dragged it out of the garage and into the dry if small conservatory at the back of the house. The alloy polished up a treat, except for the tank. There are lots of fine scratches in the alloy which are taking many hours to remove. Having always been non committal on the virtues of polished alloy tanks... yes they look great in photos but are hell to live with, gaining scratches far too easily. Therefore I made the decision to paint the tank. Probably gloss black with gold pinstripes, though no doubt I'll change my mind a few times on the colour scheme.

Next I'll make new brake and gear change pedals, as the ones I used originally don't quite match the style of the bike, as they were meant for a modern bike. I'll also rework the gear change layout to put the link rod above the lever and not below. IT wont look quite as neat but it'll work better and leave more room around the exhaust.

Next it needs a front fender, I made a mount for a classic British alloy fender, but its too narrow and doesn't cover the tyre as is should. The good news is that painting the tank opens up more possibilities for the fender.. carbon, or painted plastic might work.

Then there's an annoying oil leak coming from the primary chain case, tricky to see from where, but it needs fixing.

Finally there's the electrics.. particularly the cheap switchgear and idiot lights which I want to upgrade. One of my other bikes is having a revamped wiring system fitted at the moment, using German Moto Gadget parts. They are expensive but hopefully worth the cost. If I'm happy with the results, I may decide to use the same supplier to upgrade the Norley electrics too.

No doubt they'll be lots of other small changes along the way.. such as making a mesh screen to the open velocity stack.. but these are the main changes I've got planned for 2018. I try not to work on more than one project at a time, so progress will be slow until a couple of other projects are completed.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 08, 2018, 12:17:38
I've been busy with other bikes so not much has happened with the Norley, except that today I finally took the tank to be painted. I lot of people have said I shouldn't paint that lovely alloy tank, and I can see why. It does look good when new and polished. But if a bike is actually used on the road, it doesn't stay new and shiny for long. I'm not a fan of the dull and dented look, so its gone for paint. Nothing fancy, just a simple classic black and gold design, should be ready in around 6 to 8 weeks.. cant wait.

While I was there, Richard the owner was happy to let me film some work in progress and parts waiting for paint. There was a cool alloy tank and seat for a Guzzi made my John Williams of the Tank Shop up in Scotland, which I really liked. I forgot to take any photos, but here's the video I made today..

https://youtu.be/69p0MOPjQ5Q
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: 50gary on Mar 08, 2018, 16:17:04
Wow, one of my favorite bikes on this site, good to see some more action.   Why is there a 'dogleg' in the shift rod?
  Cheers, 50gary
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Mar 09, 2018, 07:23:17
To clear the primary case, it may have been loose, cant remember so not in its correct angle. But that's another area I'm looking to change. New one off brake and gear lever and different linkage. The first one was always supposed to be temporary to make sure the ratio was right.  . 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 16, 2018, 16:24:12
Got the call yesterday to say my tank was ready for collection from the paint shop. After much thought I came up with this simple design, but you never know how it'll really look until its done. Really pleased with the results, given its a handmade alloy tank which isn't perfectly symmetrical. Still got to fit its Monza fuel cap, and finish the other work the bike is having before it goes back on the bike, via a stainless tank strap to hold it secure.

The tank was originally bare polished alloy, classic Triton style. Which while looking great in photos when new, is a pita to live with if the bike is actually used on the road. Therefore I eventually decided to have it painted, in equally classic black and gold.

Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: grandpaul on Jun 17, 2018, 11:06:28
Why didn't you go for "Norley"  decals?
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 17, 2018, 22:21:39
A) I didn't have any
B) No one knows what Norley means
C) I couldn't find any HD tank decal that would look right on that tank
D) The Norton gold decal works with the black and gold colour scheme I wanted
E) Most specials take their ID from the frame not the engine, so while its not a OE Norton frame, its close enough.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: The Limey on Jun 18, 2018, 08:25:17
My chum had Yamaharley decals made up for his Harley/Yam bitsa.  No one knows what that means either, but if they can be bothered to ask he's happy to tell them.

Norvill, Triton, Tribsa, there is an ancient tradition of such names, and bikers understand the history and significance of such monikers.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 18, 2018, 13:26:20
Indeed, Triton, Norvil etc are now recognised classics in their own right, but not sure you could say the same about Norley. I've seen alternatives mentioned such as Harton and Nordon, though I quite liked Narley. Given the frame is the classic featherbed Norton, I went for Norton on the tank in the end. It might cause a raised eyebrow with the rivet counters of the classic world, but they can be ignored lol.   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: DesmoDog on Jun 18, 2018, 19:56:33
I've wanted to build something like this for years. I'd call mine a Snortster.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: AgentX on Jun 20, 2018, 23:58:06
Can't wait to see it mounted up.
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jun 21, 2018, 16:42:37
Sadly an idiot damaged the paintwork while fitting the Monza fuel cap...  I was livid...as the idiot was me.   :(

Spoke to the painter and it can be repainted when he gets back from holiday in a couple of weeks …

https://youtu.be/d2_lDGQ2g6g   
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 01, 2018, 12:05:04
About half way through making the new foot levers/pegs. Next step is to machine the bronze bushes which they'll pivot on, and make sure the new parts will fit on the billet mounts already made for the bike. When all the machining is finished, I will of course spend an hour or two polishing them.

 
Title: Re: Norton / Harley Ironhead Cafe Project.. Build thread
Post by: Bevelheadmhr on Jul 13, 2018, 10:15:07
Test fit of the new levers, we used roller bearings rather than bronze bushes.. still needs polishing of course, though I may have the pegs ceramically anodised..