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Blood Sweat Tears and Grease => Projects => Bob and Chop => Topic started by: Bevelheadmhr on Nov 03, 2017, 22:43:48

Title: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 03, 2017, 22:43:48
Introduction


Back in 2000, I bought a 131 Cubic inch(2150cc) high output 'Harley' Evo motor, fully polished, built by the Merch Performance workshop in Canada and shipped to the UK for me. It was the best Evo of its day, and I could've bought a new Harley big twin for the cost of that one engine.

I still needed a gearbox, primary, frame, forks, wheels, bodywork and so on. It took more than two years to complete, each part being chosen because I thought it was the best option, the cost was not a consideration, it would just take longer as I saved to pay for it all. When the German drop seat frame arrived from HPU, the engine was too tall to fit, so we had to cut and raise the top tube. Paintwork was done by the best in the country, Piers Dowell, who has painted all my Harleys along with a couple of helmets, which are far too nice to actually wear lol..

When it was finally finished, within the first 100 miles, the expensive belt primary had broken, while the handling was pretty damn awful, due to the fashionable 'phat' wheels and tyres I'd fitted, a 160 x 16 front tyre is never a good idea. The primary was soon re engineered, while I spent another £2500 on new Ricks 17 inch billet and titanium wheels which improved the handling no end, it actually wanted to go around corners now, though at the cost of even less ground clearance, and it didn't have much to begin with.

I still have the Merch 131, its evolved over the years, different brakes, different seats, different exhaust, a hydraulic clutch conversion, and after snapping three belts, I switched to chain final drive, well, you get the picture.

Its been on the dyno a few times, the last being when I made a new exhaust for it. It has a Mikuni HSR 42 carb, small for such a big engine, but that was the biggest available when I placed my order back in 2000. A HSR 48mm would no doubt give a bit more top end, but at the expense of low down torque. I prefer the motor as it is, making 145 lb/ft torque and 128 bhp at the rear wheel. To put that into perspective, its making over 100 lb /ft of torque all the way through the rev range. Its too long and low to wheely under full throttle, but it'll easily break traction in first if launched hard. In the wet, the torque can spin the tyre in second and third too, so discretion is needed, then again I try not to take it out in bad weather, it takes way too many hours to clean otherwise.

The trad Harley folk hate it, ''looks too Japanese'', doesn't look right in their eyes... blah blah. I just smile and nod, and reply, I didn't build it for you...

Mid Life Update


Anyone whose built a ground up special will know they are never finished, there's always something that can be improved or updated. Now its time for some more updates of the Merch 131 which I'll detail in this thread..
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 03, 2017, 22:57:02
Mid Life Update


The updates I want to make break down into three areas...

1) The riding position.
Its never been the most comfortable bike in the world, but still things could be improved for me at least, by bringing the bars bag an inch or so and ditto the footpeg position.

2) Improve the Ground Clearance.
This is the trickiest change to make, as like all Softail Harleys the rear shocks live under the gearbox and work differently from most shocks. They don't compress when going over a bump, instead they extend. Coupled to the fact that the shocks on my bike are expensive gas shocks (No springs used) which I want to keep. But I have a plan !

3) Electrics and Instruments
The bike has basic functions only, with a speedo bolted to the rear cylinder.. not ideal. That said its all very neat with most of the wiring hidden inside the frame tubes. I want to replace the old speedo and idiots lights with a new up to date tacho/speedo with built in idiot lights, and completely replace the wiring, taking advantage of the latest tech from the German company Moto Gadget, which wasn't available when I built the bike all those years ago.
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 03, 2017, 23:04:05
Lets get started by making new mounting plates for the forward controls, which moved the pegs an inch or so closer and a little lower. Luckily I was able to re drill and cut down the original plates which saved a lot of time.

Next the old one off risers were replaced with these new ones I made, they are as low as I could get them, while now moving the bars back an inch. The old risers and their mounting bolts were drilled to allow the wiring for the bar end indicators to pass unseen through the bars and down throught the risers.

I'll be losing the bar end indicators, as that'll made the bike six inches narrower at the bars. Handy when filtering through traffic, which is legal in the UK.


Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 03, 2017, 23:14:42
Here's the risers polished with the new speedo/tacho on the bike, its mounted to the risers is a bit different, but it kinda works. Since I took this pic, the cap head bolts have been changed for domed head bolts which look better imo.

If you want to hear it being run up on the dyno, clicky here  https://youtu.be/s2Jo-fipEAM
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 04, 2017, 11:23:42
Improving Ground Clearance

This was the mod I was most concerned about, there's a chance it could all go wrong, which would be an expensive mistake to fix. My plan is to move the Swing arms shock mounts back 20mm, doing this means the swing arm will need to rotate further down before the shocks can be bolted to the swing arm. This change should (in theory) lift the back end of the bike up around 45mm. However, if I get it wrong, the swing arm could hit the frame at full extension or the shocks may not reach the changed mounts on the swing arm.

Oh well, nothing ventured, nothing gained...

My first problem was that I had no room to work on the bike at home, not enough to safely remove the back end anyway. Thankfully, my mate Tim owns the local bike shop and kindly allowed me to work on the bike in the corner of his storage unit. Its not what you know, but who you know....

As usual things didn't go according to plan... they never do lol...  but got there in the end, the photos below show the difference before and after. And since I went to the trouble of filming the process, you can see how it was done here..

https://youtu.be/cOmDXLuC1NM
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 23, 2017, 13:53:26
With the swing arm now powder coated and a new battery, I installed the back end and fired up the engine for the first time in more than 18 months. Surprised it started ok with only a stuck float to show for its long sleep. The mods to the swingarm have worked out well, giving more than two inches of extra ground clearance and changing the stance of the bike more than I expected. I quite like its new look.

The final phase of this update is to wire in the new tacho/speedo and clean up the wiring using Moto Gadget parts.

And here it is running sans silencers after I couldn't resist firing it up

https://youtu.be/CrqCoUlsZU0

Here's two pics.. before and after
Title: Re: 2150cc Evo Custom Updates
Post by: 3DogNate on Nov 27, 2017, 22:59:17
That torque figure sounds fun... what a beast I bet it sounded like a cannon with straight headers. Honestly not a fan of drop seats and what they force the rear fender to do,  but yours is well executed. I'd do a swing arm mounted rear fender and hug it close to the tire. (you are gonna need a chain.... ;) )
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Nov 29, 2017, 08:11:27
Had to split the chain to remove the swingarm, hadn't fitted it when I took those pics. Sadly the change to the rear end height meant the old chain was no longer long enough, so had to buy a new one. Pity as the one I removed wasn't that old.

When it was first built it had V&H pipes which when I dynode the bike later, proved to be crap. Had to run them without baffles to get decent power. But doing so made it super loud and ruined the low end power, hence I ended up making my own exhaust. Here's an old vid of the bike running on the dyno with its unbaffled V&H pipes...  its so loud the camera mic cuts out at high revs as it cant handle the noise....

https://youtu.be/gJq4fZk--jI

While coming up to date, here's a short vid of the bike this weeks, with new chain and 'silencers' fitted..

https://youtu.be/yCrT2m5H9yM
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Dec 21, 2017, 14:09:37
The bike will be at my mates workshop over the new year, as one of the modules from Moto Gadget is on back order. Not a problem as it'll not be ridden till the spring anyway.

But that hasn't prevented me from making a start on another upgrade which is a mini-project in itself. One issue I have with all  Harleys is their weight, a standard Evo Softail is getting on for 650lbs with fuel, something I've attempted to address on my bike.  Cant do much about the mass of the engine / transmission (around 300lbs), while an OE frame and swingarm tips the scales at 100lbs (60/40), the aftermarket HPU frame is a bit lighter, but not much. Despite these hefty components, my 131 Merch is a lot lighter, having got the weight down to 515lb dry and around 540 lbs wet.

When the swing arm was off the bike, I found it weighed 33lbs, not bad for a Harley, but that's heavier than the frame kit of my Norley, so surely I could lose some weight here, particularly since its unsprung weight.

A few years ago I asked one of the UK's best frame makers how much they'd charge to make a replica of my swing arm in alloy... the answer.. £3000 !  I didn't ask them to justify that amount, as I suspect it was a job they didn't want.

I forgot about it, until last month, when the swing arm was off the bike for a couple of weeks... when I had an idea... why not make a replica? Therefore we took careful measurements of the arm before it went back on the bike, and went through various options of how to actually make a lightweight replica in alloy.  Much head scratching later, we had a plan, and I went ahead and ordered the billet alloy we'd need.

Now this replica wont be made the way most alloy swing arms are made.. ie from square section alloy extrusions welded together with cast / machined sections added where required. Instead the whole swing arm will be constructed from several sections made solid billet alloy, which will be bolted, pegged and welded together where appropriate. Doing so would result in a swing arm even heavier than the original, except that each part of the jigsaw which will makeup the whole, will be milled extensively to lose a huge amount of weight. Fingers crossed we'll end up with a cool looking part much lighter and stronger than the steel original.

Below you can see a start has been made on the 'jigsaw pieces', some having been line drilled to give a basic shape and marked, before going on the miller to be shaped accurately.     
 
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Jan 29, 2018, 17:07:09
The electronic parts we were waiting for have finally arrived from Germany, so I was asked to pop into my mates workshop to discuss options as to where various components were to go, and which buttons I wanted doing what.. The Moto Gadget stuff is clever, you can program it so one button does more than one task.

It was odd seeing my old bike on the lift, with its entrails hanging out, as I'm the only person whose ridden it or touched it with a spanner since it was built. I had to resist the urge to grab a cloth and start cleaning it lol. Fingers crossed the next time I visit, it'll be back together and running as good as ever..

Title: Re: 2150cc Evo Custom Updates
Post by: canyoncarver on Jan 29, 2018, 17:53:37
What a beast you have there.  I recently rode a 110TC" Bourget chop that was a straight line white knuckle ride.  You are so very correct that 100+ft/lbs of torque really opens your eyes!
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Jan 29, 2018, 20:36:27
Yep, also sitting so low to the ground makes it feel faster than it is. This one makes over 100 lb/ft torque from 1500 rpm to the redline, peak at 145 lb/ft. Looking forward to riding it again after a two year wait.

Also hope to have a go on this Sportster I've had a small hand in (its not mine). Started out life as a early 90's XL883, but now has a 1250cc Hammer performance kit, flowed big valve head and lots of mods including revalved USD forks from a GSXR750, alloy oil tank in front of the motor, 17 inch alloy rimed wheels etc..

 
Title: Re: 2150cc Evo Custom Updates
Post by: Tim on Jan 30, 2018, 00:37:24
Wow!
Title: Re: 2150cc Evo Custom Updates
Post by: der_nanno on Jan 30, 2018, 09:19:09
Now I do have a soft spot for sporty Sportsters...
Title: Re: 2150cc Evo Custom Updates
Post by: Luugo86 on Jan 30, 2018, 09:36:15
How much did you punch the jugs out and what type of heads are you using ?
Title: Re: 2150cc Evo Custom Updates
Post by: irk miller on Jan 30, 2018, 09:38:28
Oh man.
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Jan 30, 2018, 23:16:07
How much did you punch the jugs out and what type of heads are you using ?

Its got a Hammer performance 1250cc kit, while the heads were flowed and given bigger valves .. cant recall the valve sizes.

Here's a before pic of the engine and new barrels, pistons etc..
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 01, 2018, 21:32:03
Slight thread detour, since folks like the look of the XL Scrambler project, here's a vid I posted today of progress on its final assembly..

https://youtu.be/JZh7TL4uQ84
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 03, 2018, 23:39:16
Back to the Merch131... The switchgear from Moto Gadget has been fitted, they make a few different options... black, polished alloy, standard or mini buttons.. I went with the polished / 3 mini button option (the bike only has 3 buttons on the bars for the horn, high beam and starter)  which at around £120 isn't cheap. But they do feel very well made, so hopefully worth it..

Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 03, 2018, 23:41:53
While the mini sub project to make a replica swing arm in billet alloy is making slow progress, with the front side plates and the cross pieces having been milled now..

And here's a short vid of how its coming together so far..

https://youtu.be/FkbKCfGSpbg

 
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 08, 2018, 17:34:53
The alloy swing arm is progressing surprisingly well (touch wood).... 15 hours of machining so far, and this is how its looking.

Harley parts aren't known for being lightweight, and sure enough the original swingarm of my aftermarket chassis weighs a hefty 34lbs.  My target is to halve that with this new alloy copy, so far with all components it weighes 20lbs, but there's still a pound or two to lose, so the target is possible. 17lbs is still a boat anchor in sports bike terms but its better than 34lbs.

Note the 'V' shaped grooves machined into the arm where two pieces are bolted together. This is where its going to be welded, as the groove allows for a neater stronger weld.
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 09, 2018, 23:10:59
While I admire the work you've done and are still doing, you obviously have more money than sense  8)
 I still have no idea why people fit 10,000rpm exhausts on 'Harley's' though?
With the torque that motor is making I guess next thing will be strengthen left side of frame to make sure it stays in line 'in compression'.
At least your not setting things up 'on the curve' so they get pulled straight during acceleration. They are outrigger bearings on belt cover?


How much did you punch the jugs out and what type of heads are you using ?

You can't bore much further as even with special 'waisted' bolt in th centre of 'V' you run out of crankcase. 1250 is probably as big as you can bore, to get more capacity you need a stroker crank but that needs special rods and pistons (or, about another £3,000)
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 10, 2018, 05:35:25
The XL is 1250cc, though I see that Hammer Performance now have an updated 1275cc conversion kit. I seem to recall the biggest you can go with a std crank is 1440cc or there abouts?

Not sure what you mean by 10,000rpm exhaust on a Harley?

The Primary belt drive does indeed have outrigger bearings to support the pulleys, though the front one had to be redesigned after it failed at speed.

Since the frame and swing arm is aftermarket and non standard, the only way of having an alloy swing arm would be to commission one from one of the few decent frame builders in the UK. Last time I asked (a few years ago) Spondon wanted £3000, so I didn't bother!

So far the new swing arm has cost £130... £40 for the bearings and £90 for the alloy, so not too bad. Though it may end up in a new project, haven't decided yet.
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 10, 2018, 23:21:38
If you work out 'tuned length' for exhaust you'll find almost every HD system is way too short.
Some of the worst are 'drag pipes' for Sportsters. I did the math one time, sure enough, just about every after-market set were tuned for 9,000rpm. (in Florida people still believe 'loud pipes save lives'  ::) )
 We dyno tested an 883 with 'drag pipes', even with carb set as good as it could get it lost 8bhp from a stock system (38bhp is pretty pathetic from almost 900cc) 'Sounded fast' though  ;D
With your Merch motor I'm pretty sure it won't self destruct at 6500rpm but even so a longer system will make more power and (gulp) even more torque. That could be an issue as you already have a ton of torque at 'low' rpm. Wheel-spinning 'everywhere' may sound like fun but just gets to be more trouble than it's worth after a while. Personally, I always thought the  1994/98 Ducati 916 under-seat exhaust was to get longer pipe length more than styling, although it is still my favourite Duc.
 £130 is damn cheap for 'custom' swing arm, I guess your not paying for CNC time?
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 11, 2018, 05:48:25
Oh I see ref header length. I don't have the numbers to hand, but in general the shorter the header length the higher peak torque (all other thinks being equal). Minimum length for a Evo Big twin is around 26 inch, any shorter and the engine will never run right. Max length you'll find for HD exhaust headers is around 40 inches (so peak torque low in the rev range). I made mine with 32 inch headers, so slightly shorter than average, to move peak torque in the upper half of the rev range. Sure enough the dyno gives peak torque at 3500 rpm. The ignition is adjustable, and I have it set to cut out at 6,000rpm. I don't think it'll last long at 6,500.
Peak power is at 5200 so no point in revving it much more. A bigger carb may give me a bit more power at the top end, but I'm happy with it as is.

Drag pipes are great ... for drag racing lol... With an OE cam with sod all valve overlap they don't do too much damage to power, but as soon as you add a performance cam, drag bikes can really cause problems.

I don't have access to a CNC miller, its all done by hand on a miller made around 1965.. that's why it takes so long.
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 11, 2018, 12:22:44
Far more impressed when you 'twiddle the knobs' by hand  ;D
 Doing some nice work.
Just watched the vid and took a look at pictures, should have noticed chain drilling sooner.
I've done a lot of HD cranks over the years, big end is weak spot when you rev them, you can tell by wear pattern if it was oil failure/dirty oil, over revving or ignition problem that caused failure.
Haven't done any of the later 'pressed up' cranks, 50 ton presses scare me  ;)
 The total length of exhaust is also important, megga gives much broader spread of power than 'sharp exits' and will give more power than a parallel pipe in almost all applications. Personally I don't have any faith in US published header length numbers, they are always shorter than optimum but using larger diameter pipe often compensates for incorrect length.
 Of course, that messes up fuel needing much richer than optimum levels to make bike ridable. There is actually very little scientific information on exhaust design, it's mostly trial and error until you find what works
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 11, 2018, 14:03:51
There's plenty of research on exhaust design, even for Harleys, ... its just v complex, so most folks follow what everyone else is doing. RB racing have some interesting pages on their site about exhaust design etc...

https://www.rbracing-rsr.com/exhausttech.htm

They were v helpful when I was building the exhaust for my old 120ci drag bike. Both the 131 exhaust and the 120 use 2 inch diam tubing for the headers instead of the OE 1 3/4 inch. Worked out ok..

Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 12, 2018, 12:31:28
Just read through the RBRacing link., well written, gues writer is a good storyteller?
Pretty much mirrors my experiences with some people  ;)
 Most just want 'give us your money and STFU'
Exhaust gas sonic speed can vary a bit more than they say, down as low as 12~1300ft/sec although higher rpm with right F/A mixture is 16~1800ft/sec
Lean mixture can give a much higher speed, until lean miss-fire messes things up  ;D
I doubt it's still in the 'Dynomation' literature but the exhaust designs it comes up with used to be +/- 10% which was fine for majority as it almost always showed a power increase throughout rpm range
I've built stepped exhaust systems, they need to be shorter than the math says they should be, usually about 4" on a <36"pipe but need a longer tail-pipe or velocity slows too much plus collector gets 'complicated'
I did have to look up Manolo Blahnik (http://www.style.com/manolo/home_flash.html). though
 One thing that has always amazed me with HD (and clones) why doesn't anyone make a decent downdraft head for them? It would be real simple to machine a pair of head's, weld in tubes with flanges and put some fuel injection or downdraft Dellorto (off  Alfa Romeo, 'racing' air-cooled Beetle or Ferrari) 45~48mm should be good  ;) It would be way more efficient ten the 'updraft' system fitted (they are ALL updraft systems on HD due to the angle of cylinders) I've seen some weird 'air-filter' systems tat need tank cut away but carb is still down in the 'V'  ???
Title: Re: 2150cc Evo Custom Updates
Post by: canyoncarver on Feb 12, 2018, 14:02:35
When I was in the midst of my 93" shovel build, I looked at and read about the RB Racing pipes.  They make nice LSR 2-1 pipe for the Shovel.  I ended up with a Thunderheader but the RB pipe was a very close second choice.   
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 12, 2018, 16:25:51
Just read through the RBRacing link., well written, gues writer is a good storyteller?
Pretty much mirrors my experiences with some people  ;)
 Most just want 'give us your money and STFU'
Exhaust gas sonic speed can vary a bit more than they say, down as low as 12~1300ft/sec although higher rpm with right F/A mixture is 16~1800ft/sec
Lean mixture can give a much higher speed, until lean miss-fire messes things up  ;D
I doubt it's still in the 'Dynomation' literature but the exhaust designs it comes up with used to be +/- 10% which was fine for majority as it almost always showed a power increase throughout rpm range
I've built stepped exhaust systems, they need to be shorter than the math says they should be, usually about 4" on a <36"pipe but need a longer tail-pipe or velocity slows too much plus collector gets 'complicated'
I did have to look up Manolo Blahnik (http://www.style.com/manolo/home_flash.html). though
 One thing that has always amazed me with HD (and clones) why doesn't anyone make a decent downdraft head for them? It would be real simple to machine a pair of head's, weld in tubes with flanges and put some fuel injection or downdraft Dellorto (off  Alfa Romeo, 'racing' air-cooled Beetle or Ferrari) 45~48mm should be good  ;) It would be way more efficient ten the 'updraft' system fitted (they are ALL updraft systems on HD due to the angle of cylinders) I've seen some weird 'air-filter' systems tat need tank cut away but carb is still down in the 'V'  ???


The famous Duckman has a Shovelhead with downdraft Webbers, His site is full of amazing builds... if you haven't seen it before, well worth the time...  http://www.dbbp.com/
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 12, 2018, 16:43:23
While today I went to the workshop to pay the bill for all the work they'd done, as the bike is complete now. Just need to source / make a pair of bar ends and that's it.

They did me a good deal on the labour, which I'm v grateful for.

The cost for this 'Mid Life Update' is as follows

New Risers / foot peg mounts              £0   (as they were homemade)

Modify the swing arm                          £140  (£70 Welding + £70 powder coat)

New Tacho/Speedo Unit                      £140

Moto Gadget M Unit & Switches etc      £450

Ceramic Anodising Oil Tank                  £90

New chain                                           £100

Incidentals (Wiring, Oil, filter etc)         £60

Labour                                               £400


Grand Total                                        £1340



 


It'll be delivered home next week, when we'll load up my Guzzi Cafe Racer to take back to the workshop. I'll be able to work on it myself at the workshop, something I dont have the space to do at home at the moment. I may bite the bullet and re do all the wiring I've already done, and use another Moto Gadget M unit and switchgear. Its not cheap but I think the Guzzi deserves it...
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 12, 2018, 20:52:37
Unless it had Bosch electrics the Guzzi will need it  ;) I know Italian electrical systems are better than they were but if you ever had an Italian bike with Spanish electrics,...................well you either know or don't want to.
BTW, I like Guzzi's even better than Duc's
Didn't know about shovel with Webber's, too much 'stuff' not enough time  8)
Looks like a manifold onto stock heads?
I can't remember but don't tink there is clearance between intake and rockerbox on Shovel? I have some Evo heads but never got around to taking 'proper' angle measurements to machine them. Do remember intake runner can run almost parallel to intake valve stem which is way less work than the welded up/re-machined intakes I've seen on a few 'local' drag bikes (I'm not much into drag racing, unless I'm the one racing but being lousy at it, I 'don't' I did get on TV once (so I'm told, never saw it) around 1995~96, at Landow. BBC were doing something there and I was 'just having fun'
 
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 14, 2018, 09:39:12
The only standard part left of the Guzzi electrics is the Saprisi charging system... which is a weak point.. As for downdraft carbs on Harleys, the problem has always been the lack of space between the heads. The solution, as used by the XR race bikes is to reverse the inlet of the rear head, so you have two carbs. I'd love to fit those heads on my Ironhead, but they are as rare as hens teeth and v expensive when they appear.

Interestingly I've got a mate who owns an engineering company who has plans to make his own twin carb heads to fit an Evo Sportster. He's done a lot of work on race spec E Type Jag engines, so he could be the man to do it.
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Feb 14, 2018, 16:10:14
I know a little about the XR's, even the 4 valve heads Harley never made  ;)
You can fit two 'front' heads without too much trouble but as exhaust ports at front are such a horrible angle it's more a styling exercise .
 I spent way more time at HD than I should have considering I was teaching Suzuki  ;D
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 16, 2018, 05:07:31
The alloy swing arm is making good progress, this weekend the holes for the wheel adjusters will be milled out, along with removing some material from the inside of the spars to lose some weight. It shoulds be ready to be welded up early next week..

While here's the last short vid of the bike now the electrics are all done..

https://youtu.be/5ZOD8qWaees

Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 19, 2018, 12:36:50
The slots for the adjuster blocks have been milled out of the two swing arm spars, while another half kilo has been saved by milling out the inside of the spars. I quick guesstimate says it'll be less than half the weight of the original steel arm when finished.

Title: Re: 2150cc Evo Custom Updates
Post by: Jimbonaut on Feb 19, 2018, 13:01:55
Whilst your bike - respectfully - may not be exactly my thing, your dedication and enthusiasm to customizing it exactly to your taste is infectious.  I've been reading with great interest, and will continue to do so.  10/10 for balls-out originality!
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 19, 2018, 15:27:33
Cheers, I guess I have odd taste lol.. actually that swing arm will probably be used in a bike that doesn't exist yet, I will build it, and the swing arm will be the first piece of the jigsaw..
Title: Re: 2150cc Evo Custom Updates
Post by: Jimbonaut on Feb 19, 2018, 15:32:55
Anyone that builds a Harley Norton mash-up that looks as good as the one you built has anything but odd taste! 

Nothing odd about it my man, just...different.  And thank goodness for that.
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Feb 19, 2018, 15:53:57
It would be a dull old world if everyone liked the same thing.. Like today I had the chance to look over a couple of new factory built Italian V twin specials... one a café racer with full exquisite alloy bodywork.. they were both a bit 'different' but I thought they were great. I was told one had cost over $70K to build, with the Ti exhaust being a hefty $10K.. And they weren't Ducatis or Aprilias... I wasn't allowed to take any photos, as they hadn't been announced to the world yet.

As for the new project... I have a race bike that doesn't fit into any race category anymore and would be too loud for the noise limits that more tracks are having to instigate.. so I'm planning to have a nice man build a new frame for the race bike and convert it into a road bike.... well that's the plan anyway.

 
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Mar 07, 2018, 11:23:59
A quick update on the XL1250, its paintwork was collected from the painter this week, should be on the dyno in the next couple of days.. I like how the hole in the side panel for the ignition barrel have been incorporated into the Hammer and Tongs design .. a v old symbol used by the Army Royal Engineers.
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Mar 25, 2018, 21:13:20
Rubbish pic, but the XL1250 was finished (for now) just in time for a local bike show. Goes on the Dyno soon, be interesting to see what it makes.

Title: Re: 2150cc Evo Custom Updates
Post by: hooligan998 on Mar 26, 2018, 02:44:15
Buh-yoo-tee-ful!
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Apr 13, 2018, 05:45:12
Here's a better photo of the XL1250 taken by the River Mersey today. Its been run on the dyno using ''guestimate'' jetting where it made only 65 bhp. Once the jetting is corrected it should make more, but still not as much as it could, as its still running the original 883 cams and CV carb. Then again the aim is lots of low end torque rather than top end power..

 
Title: Re: 2150cc Evo Custom Updates
Post by: JustinLonghorn on Apr 13, 2018, 09:26:51
Looks like fun to me.
Title: Re: 2150cc Evo Custom Updates
Post by: Maritime on Apr 13, 2018, 09:35:15
I'd ride it!
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Apr 13, 2018, 11:16:55
Here's a better photo of the XL1250 taken by the River Mersey today. Its been run on the dyno using ''guestimate'' jetting where it made only 65 bhp. Once the jetting is corrected it should make more, but still not as much as it could, as its still running the original 883 cams and CV carb. Then again the aim is lots of low end torque rather than top end power..

 

Can't you set it up to 1200 Buell 'Lightning' spec?
That makes  as much 106 bhp when set up right (friend had one, I liked it  ;) )
Modified 883 heads  work great as the smaller port can be shaped to work right on a 1200 (better than stock 1200 head) but, if you can't DIY them, after-market works out cheaper
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Apr 13, 2018, 12:24:01
The heads have been flowed and a bigger inlet (I think) fitted. I'm sure its the standard cams that are holding it back. My mate owns the local bike shop, complete with dyno. They usually work on Jap and Italian superbikes, but I'm sure they can get plenty of power out of this if they wanted.
Title: Re: 2150cc Evo Custom Updates
Post by: john83 on Apr 14, 2018, 20:00:52
Ooh man, that looks good!
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Apr 28, 2018, 14:45:24
My home made alloy swing arm, which has become a mini project in itself, got welded today. It all went ok with no distortion etc. Still to decide if its getting the under bracing of the original steel version its copied from, and what finish it having. Polished, powder coated or maybe anodised?

Its half the weight of the original (17 Vs 34 lbs), still heavy for a sports bike swing arm, but pretty light for a Harley Softail..

Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Apr 29, 2018, 00:17:23
Although I haven't worked on a softtail for about 10 yrs, the under-brace isn't actually brace but to reduce stress at the connection of arm and upright due to the shocks being underneath tranny and connected to bottom of your 'T'
It acts more like a pull rod
 You'll have to remove all the bolts to anodize it, unless you already have titanium ones? (anodizing doesn't like stainless)
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Apr 29, 2018, 16:38:41
Yep the under braces work in extension not compression, I have a couple of ideas for making them a bit different from just a welded in bar. The countersunk bolts are all stainless, but its no trouble to remove them if needed to get the arm anodised or powder coated, now its been welded together.
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on May 19, 2018, 12:38:40
Had an interesting morning, weighing the XL1250 and a near standard XL883 yesterday, using the calibrated scales built into the brake testing machine used for the annual test with have here in the UK.

Wasn't sure how accurate the method would be, as it tests one wheel at a time, but the numbers we got from the near standard bike were close to its official weight (485lbs for a 1991 XL883).

The XL1250 would be lighter of course, but how much? It weighed in at 400 lbs with only a little fuel in the tank. Not bad at all. Still hasn't been set up on the dyno due to lack of time, but it sounds ok being run up and down the road..  here it is if you want to hear it..

https://youtu.be/280lEt7YNe4

Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Jun 15, 2018, 17:57:10
My mates XL1250 finally had its first run on the dyno today. Its running way too rich, and with standard cams and rejetted OE carb, we weren't expecting huge power numbers. Although it was built for low end torque over top end HP in any case.

Despite running rich, it made decent power, with a smooth graph, no sudden dips in HP as the revs climbed. With leaner jetting should make more a bit more HP.

What did it make?  You'll have to watch it running on the dyno to find out .. 
https://youtu.be/LmodhLHAK7c    :)
Title: Re: 2150cc Evo Custom Updates
Post by: Bevelheadmhr on Sep 26, 2018, 16:37:11
Finally got around to working on the alloy swingarm again. It needed two underbraces to replicate those of the original steel arm. But that proved to be difficult as alloy bar cant be so easily bent and manipulated as steel. So after a couple of false starts, I came up with a final design. I bought 1m of 30mm alloy bar, cut it in half, then line drilled them (had to use a friends 1940's Capstan lathe, as ours isn't big enough. I left the last few inches of one end solid. This would be the lower end which was machined down to a 20mm flat, so it could be welded to the lower part of the side plates of the arm. The other hollow end was profiled on the miller to fit the underside of the two arms. That done, just had to take it to Geoff the welder who welded them into place.

Pity I forgot about the need for a bracket on one brace to hold the brake torque arm, but it'll be added when I get time.

Next task is to make a wheel spindle, not sure yet what to use.. EN24 or Stainless steel.. Ti would be light, but I hear its banned from being used in race bikes for good reason, so probably best to stick with steel. Also need to make a battery box for the lithium battery its getting, which should save about 12lbs over a lead acid equivalent... still need to buy a suitable one of those. Then finally have to decide on the finish.. either polish it or polish it and have it ceramically coated.

Total weight of the arm is 17lbs with the temporary thread bar 'spindle'.. about half of the original steel version.
Title: Re: 2150cc Evo Custom Updates
Post by: crazypj on Sep 27, 2018, 01:52:41
You should anodize it  ;)