Bobber Build by a total Newb

emzdogz the shinko is growing on me already...the avon speedmaster comes in tomorrow so once I get that one on I'll have a better idea of what I'm looking at. I'm sure it'll grow on me too even if it doesn't turn out to be the same as the picture I had in my head.

RockingThePartyDJ that was pretty slick...I'd like to see that with a true motorcycle tire


Well, I've been kicking around the idea of a chain tensioner because my chain keeps dinging the nylon spacer I put on the bottom of my electronics tank to avoid a major metal malfunction. The nylon is tough and all, but I'd like to keep it off of it altogether.

I searched around and ended up seeing a thread by ontherocks where he made a chain tensioner out of an old stock peg since it's already spring loaded. I wanted I couldn't resist the cheap idea so I did the same but instead of welding or bolting it on I cut a piece of tube off of the old swing arm and welded it to the bottom and planned to at least do some testing with hose clamps to the lower frame rail.
I picked up 4 long board wheels that were 60mm by 44mm wide with abec 7 bearings for just under $20. The durometer rating was 83a which was a little lower than I wanted but they were cheap so I wasn't going to be picky. Of course my paint scheme will be orange, so the wheels had to be orange too:thumbsup:
null-64.jpg


Here it is clamped up...I wasn't sure exactly how tight I could get hose clamps, but they actually tightened up much tighter than I had anticipated. Besides that the stock footpeg spring is pretty weak and I didn't expect there to be much force on it anyway...or even how much good it would do.
null-63.jpg


I went out and slammed through the gears a few times with it keeping an eye on it and the hose clamps didn't budge at all. The wheel kept bouncing up and down as I was riding along and when I got home the chain hadn't appeared to make any contact with the nylon spacer below the electronics tank. Even with that weak spring it seemed to be doing something of value. After a few miles of riding I looked at the wheel and it doesn't even have so much as a scuff on it from the chain...
While at the depot picking up the hose clamps I actually picked up a husky spring clamp as well to see if I could give this tensioner a bit more...tension.
null-62.jpg


Out came the spring and I gave it a whirl. I had to drill a hole in the front of the peg base because the spring was wound in the opposite direction of the stock spring. I gave the upper end a back bend for more tension at the top of the pegs movement and bolted it up.
null-61.jpg


It is much firmer now. Slapped it back on there and tightened down the clamps even more than last time, but I haven't taken it for a ride yet. I was actually going to make a 4 bolt clamp type mount using another section from the swing arm on the bottom of the frame rail, but these hose clamps seem to be holding extremely tight right now. I'll keep and eye on them and I'll probably go ahead and make the clamp for it, but for now it will let me continue to test. Tomorrow I'll have to take it out and see how this new spring does...it's actually holding tension on the chain much better than the stock spring. The stocker may have been able to take some of the slack out of the chain at certain moments of riding, but this spring should be able to do a much better job of maintaining a steady tension in the chain...we'll see.
 
Well, I finally got the avon speedmaster in the mail. It was an ordeal trying to get the old tire off the rim...dinged up the edge, punctured the tube, and ended up having to use my angle grinder to cut the bead to get the old tire off...
That speedmaster went on without any issues. Some baby powder and my thumbs on the one side was all I needed...then the irons came out for just the last few inches. I set up my balancing stand and checked it and it was waaaaaay off. I had to find a place in town that had them but all I could find was the no lead adhesive backed ones that are huge. It took 3oz to balance the front and 2.5oz on the rear...I've got to get some spoke weights...these things look rediculous.

While taking the rear off to balance it I noticed my plate bracket had a 2.5" crack across it...so I took it off and welded it. I wasn't surprised to see the crack after looking back and seeing it bounce up and down like a jack hammer with the rear out of balance. After taking a ride this afternoon I was impressed with how smooth it was. Very nice indeed.

I even like the looks of it now...
null-65.jpg


Oh, and this was the first time to check the new spring on the tensioner...that thing is money...works perfectly
 
It's still sitting in the garage waiting for me to put it back on the table in the barn. I'll probably get to it over Christmas and use it as something to do during the dead of winter. Thank God for my wood pellet stove in there...probably gonna be a cold one here in northwest Ohio.

I still need to get the rear fender fit/fab'd up and a permanent bracket made for the chain tensioner. After I knock those out I should be good to begin the breakdown. Oh, I also need to deal with the exhaust. I'm still thinking maybe the curved drag pipes from Gordon Scott. I really like the looks of them, I'm just concerned with the proximity of the pipes to my legs and the end caps to the wiring tank as well. If I'm broken down somewhere with an electrical problem I don't want to be fooling around with the end caps to replace a fuse and be burning myself on the pipes. Does the fiberglass wrap help substantially as a heat shield?

Any thoughts on the curved drags and fiberglass wrap and leg/wiring tank proximity?
 
Hey I was wondering where you were dilbone. The wrap on mine does a decent job of insulating, but I wouldn't want those pipes that close to my legs.:eek:
Winter ain't that long man, you better get after it.:wink2::bike:
 
I'm a little ways behind you on the build so I can't comment on the heat but I bought GordonScott curved drags. Bought them for the look and the build quality seems to be on par for his reputation. I was thinking about ceramic coating them, never thought about too much heat. Guess I have something to ponder now.

Oh, and your bike is looking pretty badass so far. I'm keeping an eye on this and might borrow some ideas if you don't mind.:cheers:
 
I have curved drags and I'm making some short, straight heatshields work for now.

I do wish there were longer, curved ones available. I guess the trick would be to get a piece of much fatter tubing bent approx like the curved drags, cut a section in half and use those pieces. Weld on some little straps on the back to hold pipe clamps, like the straight heat shields have.
Down the road I might see about finding someone locally who can bend a section of fat exhaust pipe for me, to make some curved heat shields out of.
 
Last edited:
Hey I was wondering where you were dilbone. The wrap on mine does a decent job of insulating, but I wouldn't want those pipes that close to my legs.:eek:
Winter ain't that long man, you better get after it.:wink2::bike:

That's kinda what I figured about the wrap haha. I put about 500 miles on it this fall riding as it in its current state. I've enjoyed it so much I'm not looking forward to breaking it down because I know I won't be done by spring when I'll be itching to get back on it.

I'm a little ways behind you on the build so I can't comment on the heat but I bought GordonScott curved drags. Bought them for the look and the build quality seems to be on par for his reputation. I was thinking about ceramic coating them, never thought about too much heat. Guess I have something to ponder now.

Oh, and your bike is looking pretty badass so far. I'm keeping an eye on this and might borrow some ideas if you don't mind.:cheers:

Thanks lowerc, I told my brother last spring spring when I got it up on the table to start building that I was going for just a stripped down badass looking bike...:thumbsup:
dude, you can more than borrow ideas...I stole most of what you see here anyway:D

I have curved drags and I'm making some short, straight heatshields work for now.

I do wish there were longer, curved ones available. I guess the trick would be to get a piece of much fatter tubing bent approx like the curved drags, cut a section in half and use those pieces. Weld on some little straps on the back to hold pipe clamps, like the straight heat shields have.
Down the road I might see about finding someone locally who can bend a section of fat exhaust pipe for me, to make some curved heat shields out of.

Heat shields are a great idea emzdogz, I'll have to check in on you and see what you come up with.

lot of great links here, also great looking bike!

Thanks cobrasneverdie, I'm hoping it'll really come together here once I get the fender and exhaust figured out.
 
I ended up looking around for just some bends I could buy and use the old flanges off the stock headers to build my own exhaust.
I picked 2 of these up for $12.99 each + shipping...less than $40 total from www.speedwaymotors.com
mandrelbends.jpg


I don't know exactly what style I'll build, but I know that with the way my peg mounts fit there's not a whole lot of room to run straight drags low down the sides. I really don't want the pipes up by my legs at all, but I don't want them to interfere with putting the bike on the motorcycle jack either. I'm not sure that I can have both of those wishes on my list with any possible exhaust I build that would look any different than the cut off headers I have right now.:shrug:

I'm gonna have to think about this some more and see what I can come up with...it might be after Christmas before I start working on anything, but any additional ideas would be welcome in the meantime:wink2:
 
Last edited:
Hey, I looked at those combo bend's when I was building mine!
Good price for what you get.:thumbsup:
You'll be able to come up with something cool for sure.:D
 
Well, I've done jack squat this winter on the bike...

On Christmas Eve I had a buddy help me get it back on the table...then it sat for a out a month and half...I did about a day's worth of work...then it has sat since

I really hope I can find the motivation to get out there in the next couple of months or it's gonna be a long summer of work and no riding of this one. At least I still have the electraglide to ride...but that's not nearly as fun as this one!!!

Here's what I got done over winter...

I cut down the seat and still have more work to do, but the concave curves were way too wide and would cut into the backs of your legs when your feet were down. I'll finish cleaning it up once I take it off the bike and prepare to apholster it.
17B1E739-44D2-42B2-9CB1-55F93F9F0B11.jpg


Next it was onto the rear fender. I originally had a 6" flat fender to use, but I really don't like the look now...doesn't seem to fit this bike so I took the front fender, cut off the mounting ears, ground out the mounting bracket, and bent over the edges to try and match the rest of the fender. It's gonna need some filler to smooth it out, but I'll work I think.
7E37AACA-26D3-484B-8658-250C42C4290F.jpg

782B3A28-B8EF-45D3-8F31-D729D7C12B52.jpg

966356EE-4989-4279-9C8C-D2936BF4CF97.jpg


I definitely like the look of this fender better than the one I originally planned for. Now it will be onto making struts for the rear and a bracket for the front near the battery box...then finally onto the exhaust which I still have no ideas for
38200BCD-F869-44DD-BD56-A85E0C101D8A.jpg

0BD83C90-63B1-4E61-88E0-39E14DD05B04.jpg


That certainly isn't 3 months of work...but that's all I've got!!! Time to get busy
 
Well I've gotten very little done this spring...hopefully summer will be better.

I'm still working out the rear fender, but I think I'm on the way to finishing that.

After cutting the mounting ears off the front I decided to go back to the flat trailer style fender I had already bought. I wasn't thrilled with the look and was planning on having to re-radius the dang thing, but after cutting it to length it seemed to fit a little better than I first thought.

I actually used a mounting ear off of the front fender as a bracket on the rear and cut the chain relief. I was about to weld the bracket to the frame until I remembered that I hadn't taken any of the wiring off...shoot...I've been putting it off because I just don't want to tear it down and have to remember what the heck I was doing when I wired it the first time lol
20140619_155022.jpg


20140619_160316.jpg


20140619_160045.jpg


20140619_160224.jpg


I've got some 5/16" round stock to make struts for the rear mount. Man I gotta get to work...
 
Hey dilbone! Like your idea on the fender mount, using what you have, sounds familiar.:D
That fender will look good on there man. Now get back to work dude!:laugh:
 
Hey Guy I like where your going with the bike. Keep up the good work

Thanks RockingThePartyDJ, it's been fun but I gotta get back to it.




Hey dilbone! Like your idea on the fender mount, using what you have, sounds familiar.:D
That fender will look good on there man. Now get back to work dude!:laugh:

Yeah John, seems like I just can't either get the time or the gumption to get this done...maybe one or the other but never both at the same time!!!!

This fender has grown on me...everytime I go into the barn and see it sitting there is helping! I'm still not sure how I'm gonna shape the struts but I've got a couple ideas.

Now that the pull out shelves in the pantry and dining table benches are done...I just might get back on this thing
 
finally got some work done today...and since I didn't feel like unhooking all of my wiring to weld the fender bracket onto the frame I decided to work on the struts...
Here's my "strut kit" haha, just some 3/8" round bar and some 3/4" "bung" blanks.
20140625_135225.jpg


I didn't want straight struts so I figured out how much offset there was from the 2 ends of where they would be connected, put it in the vice, and started bending. Some trial and some actual measurements go me here
20140625_142728.jpg


Now, how to I repeat this??? Back to the vice...first bend looks pretty close. Thank God for monkey wrenches...
20140625_143219.jpg


Looks pretty close to me
20140625_144856.jpg


They just might even be symmetrical
20140625_144929.jpg


I welded the "bung" blanks onto the ends.
20140625_193349.jpg


I think it'll work. Next I'll be drilling and tapping those bungs for 5/16" bolts then I'll weld the outside hole shut and grind it off rounded over.
20140625_193521.jpg
 
Back
Top