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Blood Sweat Tears and Grease => Projects => Specials => Topic started by: irk miller on Mar 30, 2018, 20:32:42

Title: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Mar 30, 2018, 20:32:42
Here we go into my first foray with Harley Davidson. A friend of a friend here in town brought me this Sportster he bought back from his insurance company. Apparently, an old lady back into it and they totaled it or some shit. Anyway, heís got several grand in settlement and asked if I would do a mild custom. Many features will be his decisions. I also hope to give it some of my flavor.

This is Masterís week in Augusta, GA which means Iím on Spring Break from teaching. Iím going to try to get it done in under two weeks. The clock starts now...




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Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Jimbonaut on Mar 30, 2018, 21:32:15
Nice, I had me one of those last summer, a 1200.  So much you can do with them and what did I do?  Sold it.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Mar 31, 2018, 20:54:35
Iíll be honest. Iím feeling a little guilty that most of this build will come from ordering parts online. Itís pretty awesome that thereís such a big aftermarket for these, but it takes some of the fun out of it. 

The customer wants a peanut tank. I normally would shy away, plus a stock Sportster tank isnít far off. I really wanted to push the envelope here, but itís not my money. I am pushing for the Softail fender. He asked for a bobbed stock fender, but I want to take a hard look at the Softail. I had to trim the frame back for either.


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Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: canyoncarver on Mar 31, 2018, 22:05:15
Sweet!  I was hoping you'd post it up. 
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Mar 31, 2018, 23:07:08
Sweet!  I was hoping you'd post it up.
No use fucking it up and keeping it to myself.




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Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: john83 on Apr 01, 2018, 13:37:13
Looks like a fun time.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: WhyNot on Apr 01, 2018, 19:49:18
Wow...................you are one busy dude.

I've got a 750 with the carbs off, and a 350f with pizzing carbs, ain't got time for either.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: advCo on Apr 01, 2018, 21:30:51
Looking better already.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: JustinLonghorn on Apr 02, 2018, 09:18:38
I'm on board sir.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Maritime on Apr 02, 2018, 09:56:54
Sign me up! Spending other folks money to build is kind of fun, until they want something you know will look stupid and have to convince them it's a bad idea
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 02, 2018, 10:13:06
Sign me up! Spending other folks money to build is kind of fun, until they want something you know will look stupid and have to convince them it's a bad idea

Ha, yep.  Fortunately, the only items he picked are the Frisco tank, the handlebars (we picked them together) and he wants it in flat black.  I had him convinced in something else, but he called a few weeks later to tell me he really wants flat black.  So flat black it will be.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: 3DogNate on Apr 03, 2018, 00:27:06
Ah boo.... everyone's brother's cousin's asshole buddy has a flat black sportster. I'm sure you'll make it work without being boring.... watching along.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 06, 2018, 01:16:09
Got the tank properly mounted with bungs welded in the frame.  I didn't take any process shots, not that anyone really needs to see them.  It uses leather washers, which I kinda like.  I coated them in mink oil and on they go...

(http://www.dotheton.com/gallery/77150-050418225456-35791438.jpeg)

Also got the bars loaded up.  The stock controls were broken, so I went with some black powder coated versions similar to the stock bars.  Yeah, really creative.  These tiny mirrors are definitely pretty sweet.  I can see them on a few different style bikes...

(http://www.dotheton.com/gallery/77150-050418225458-35911473.jpeg)

(http://www.dotheton.com/gallery/77150-050418225500-35921805.jpeg)

(http://www.dotheton.com/gallery/77150-050418225501-3593894.jpeg)

Tail light and turn signals.  I have a black version of the bolt en route.  I'm pretty pissed that the tail light advertised for a Sportster to go inside the bobbed fender was 2 inches too wide.  Definitely not Sportster. 

(http://www.dotheton.com/gallery/77150-050418225503-3594771.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: canyoncarver on Apr 06, 2018, 13:26:04
The tail light didn't fit all chopperbobberharleycafetrackerbrats ?
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 06, 2018, 13:28:03
Subscribed.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 06, 2018, 14:38:17
The tail light didn't fit all chopperbobberharleycafetrackerbrats ?
Haha.  It must.  I don't think I have one of those in the shop.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Hurco550 on Apr 06, 2018, 15:32:54
Haha.  It must.  I don't think I have one of those in the shop.

or maybe you have 5 of them in the shop? #perspective
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 08, 2018, 18:35:51
Wasn't really happy with the single bolt through the fender and I really couldn't take not making something for this bike from scratch.  So, I made a tail light...

(http://www.dotheton.com/gallery/77150-080418163047-36031454.jpeg)

(http://www.dotheton.com/gallery/77150-080418163050-3604448.jpeg)

Trying to decide if I want to powdercoat the light black or just the stand.  There is a black bolt LED coming in to replace the silver one.  That is for certain.

(http://www.dotheton.com/gallery/77150-080418174351.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Maritime on Apr 09, 2018, 08:57:14
Nifty. I like that
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 09, 2018, 12:01:37
Thanks, Mike.

Tried my hand at powder coat for the first time with a satin black on the headlight mount...

(http://www.dotheton.com/gallery/77150-090418095936.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: advCo on Apr 09, 2018, 12:04:30
Thanks, Mike.

Tried my hand at powder coat for the first time with a satin black on the headlight mount...

(http://www.dotheton.com/gallery/77150-090418095936.jpeg)

Looks sharp. I need to invest in a powder setup.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Maritime on Apr 09, 2018, 13:07:19
That looks pretty good, only a few small bumps you can barely see.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 09, 2018, 13:48:13
That looks pretty good, only a few small bumps you can barely see.
Yeah, I'm guessing because I didn't pre-bake the aluminum.  Live and learn.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 09, 2018, 21:43:15
95% complete.  I just need to wire the turn signals and the tail light, then install the CV performance jet kit.

(http://www.dotheton.com/gallery/77150-090418192818-3621859.jpeg)

(http://www.dotheton.com/gallery/77150-090418192821-36222149.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Maritime on Apr 10, 2018, 09:59:35
That looks alright there Mr. Irk. May not be every ones cuppa tea but hey I did a Canary yellow Honda Magna. As long as the customer/Buddy is happy you did your job. I actually like it.  I'd maybe have blacked out a little of the shinier bits on the engine, but that might take a lot of work, not sure. Cheers
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: TranceMachineVienna on Apr 10, 2018, 10:19:44
Looks killer!

Maybe scotch briting the chrome air filter cover to a nice dull matte finish would do a lot, since everthing else not shiny anmyore.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: JustinLonghorn on Apr 10, 2018, 10:25:01
I'd ride it.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: WhyNot on Apr 10, 2018, 11:41:20
I'd ride it too.

Overall looks good.

As always, good job Eric.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: SONIC. on Apr 10, 2018, 11:54:25
So when does Irk's Custom Motorcycle and Pottery Emporium open?

Looks good man  8)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 10, 2018, 13:21:21
So when does Irk's Custom Motorcycle and Pottery Emporium open?

Looks good man  8)

(https://img0.etsystatic.com/110/0/17304532/iusa_400x400.44823698_ntlv.jpg)

;)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: brad black on Apr 10, 2018, 20:26:51
i really like the turn up on the softail rear guard, pity it didn't make it.  i'm trying to work out how to make one work with my next monster project.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 10, 2018, 20:36:44
i really like the turn up on the softail rear guard, pity it didn't make it.  i'm trying to work out how to make one work with my next monster project.
I agree.  It's not stock, but instead a fiberglass version of a Softail fender.  I could narrow it by cutting a 1/2" to inch of the center, but also the curve of the fender and how it fits the inner frame was a struggle.  If it's my Sportster, I say fuck it and cut the frame and make it match.  But the guy asked for a bobbed fender and I took a chance to see if could make that one work easily then hope he likes it.  If he didn't, then I could always bob the stock Sportster fender- no harm, no foul.  Basically, the caveat was that the Softail fender required the frame to be much shorter than the bobbed Sportster fender.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: brad black on Apr 10, 2018, 23:20:42
yep.  it's always different being on the clock to someone rather than doing it for you.

i've seen a few fibreglass ones around, but i don't know that any of them are wide enough for the back of a monster.  or how i'd make it tie in anyway.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 15, 2018, 19:12:55
In designing the tail light, I machined it to utilize a 16mm bolt LED.  These are two wire LEDs that have really good brightness, especially with the magnifying lens.  To use as a running light/brake light, however, you typically need a 3 wire light- ground/running/brake.  What I have done instead, is create a circuit that will allow this two-wire light to be used.  To do so, I used two Zener 12V 5W Axial Diodes, and a 1KΩ 5% 1/2W resistor on the running lights circuit.

(http://www.dotheton.com/gallery/77150-150418165925-36361016.jpeg)

I attach leads on each circuit to match the stock harness, paint everything with liquid tape, cover it all in shrink.

(http://www.dotheton.com/gallery/77150-150418165935-3641750.jpeg)

It's hard to get clear images to show the results with my camera because it's flooding the lens with so much light, but with a flash you get a decent idea.  The first pic is the running light, and the second pic is the brake light.

(http://www.dotheton.com/gallery/77150-150418165928-36391316.jpeg)

(http://www.dotheton.com/gallery/77150-150418165931-36402477.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Hurco550 on Apr 15, 2018, 20:07:23
That's the same thing I did on those lights on the dr650. they are super bright.

Sent from my SM-G920V using Tapatalk

Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Jimbonaut on Apr 15, 2018, 20:16:48
To do so, I used two Zener 12V 5W Axial Diodes, and a 1KΩ 5% 1/2W resistor on the running lights circuit.

I haven't understood a sentence less in about 30 years. 

Bike sure looks good though.  Every time I see a well appointed Sportster I miss the one I sold last year.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 16, 2018, 11:09:56
How come the diodes instead of just the resistor?
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 16, 2018, 11:14:45
How come the diodes instead of just the resistor?
The diodes prevent flow back, so they separate the circuits.  Otherwise, it would be brake light all the time. 
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 16, 2018, 11:26:57
You're using an LED light, right? The lamp already is a diode. :P
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 16, 2018, 11:41:59
You're using an LED light, right? The lamp already is a diode. :P
It's a light emitting diode, yes, but but when you run reverse flow on them they blow.  Without the Zener diodes, the LED would have a very short life.  Not all diodes act the same.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 16, 2018, 11:48:35
It's not AC voltage on the tail light, is it? I feel like I'm missing something.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 16, 2018, 12:02:05
It's not AC voltage on the tail light, is it? I feel like I'm missing something.
I'm not going to pretend to be an expert in this stuff, or have training in it.  I work with an electrical engineer in our robotics program here at the school.  This is how he told me to set this up.  I've been told, and I've read, that the LED's have a short life without setting it up this way.  I also seem to remember there was a way that the light will be bright all the time otherwise.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 16, 2018, 12:09:09
I've worked with a few of of the two wire tail lights before and they've only come with resistors. It's entirely possible the diodes are a proper addition if you're going to do it the right way. I was just hoping to find out more about it.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 16, 2018, 12:27:15
I've worked with a few of of the two wire tail lights before and they've only come with resistors. It's entirely possible the diodes are a proper addition if you're going to do it the right way. I was just hoping to find out more about it.
What I do know about Zener diodes, and maybe this is why, is they prevent spikes in a current and they provide a very consistent voltage.  I know their most common usage is for voltage indicators, or whatever you call it, where coupled with an LED they provide references that read voltage. 
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Pete12 on Apr 17, 2018, 09:37:02
What I do know about Zener diodes, and maybe this is why, is they prevent spikes in a current and they provide a very consistent voltage.  I know their most common usage is for voltage indicators, or whatever you call it, where coupled with an LED they provide references that read voltage.

You're thinking about plain diodes Irk, a zener diode prevents voltage going in the reverse direction until the zener setpoint is made.
You just need IN4004 diodes and a current limiting resistor.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 17, 2018, 09:58:48
You're thinking about plain diodes Irk, a zener diode prevents voltage going in the reverse direction until the zener setpoint is made.
Yes, I mentioned that in my first comment. 
The diodes prevent flow back, so they separate the circuits.  Otherwise, it would be brake light all the time.


The statement you quoted is in addition to that.  This is what I'm referring to in that comment...

(https://www.electrical4u.com/wp-content/uploads/2013/05/zener-diode-voltage-regulator.png)

There's like 15 types of diodes, so I'm not sure which one you are referring to as a plain diode.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 17, 2018, 10:04:44
You just need IN4004 diodes and a current limiting resistor.

The setup i have here is working.  Does it need to be changed?  By Matt's suggestion, the diodes aren't really necessary at all.  That's the question we're trying to answer.  I go back to Savannah River Site next week, so I won't have an answer before then from the guy that helped me set this up.  He also wasn't specific to the diode.  I just happen to have these in my box of bits.  I stole the resistor from a circuit board I built a couple years back.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Pete12 on Apr 17, 2018, 10:11:20
Sorry, I should have read it all.
You use diodes in a circuit where there are two supplies running one set of LED's. If you are only using one supply/one circuit you don't need the diodes at all, but you will want a current limiting resistor as LED's only run on 20-30mA.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: irk miller on Apr 21, 2018, 15:16:08
All finished.  Took it for a ride, and I have to say, it was great.  Much love to the Sportster.

(http://www.dotheton.com/gallery/77150-210418130842-36471208.jpeg)

(http://www.dotheton.com/gallery/77150-210418130845-3653220.jpeg)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: trek97 on Apr 21, 2018, 23:07:18
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: canyoncarver on Apr 22, 2018, 00:13:16
Nice work man.  It's clean.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: Sonreir on Apr 23, 2018, 11:45:56
Good deal.
Title: Re: 1996 HD Sportster 883 Iíll need a hugger when itís over Hellride
Post by: 3DogNate on Jun 06, 2018, 23:36:30
Nice to see some more Harley-Davidson lovin happening. These Evo motors are great... downright bulletproof. Your build looks good man...