Finally...the bike (aka "Dusty") is done

As with all builds there were a few issues to resolve.  Leaky seals for the most part but they were resolved fairly easily.  One that was a little puzzling was the bike would not stop running after the ignition was switched off.  Turned out the coil was retaining enough energy to keep firing the bike!  Who would have thought?   However, incorporating a "kill" switch into the coil circuit solved the problem.  Also, the "hi temp" clear paint applied to the exhaust pipes wasn't so hi temp and promptly burned a hideous shade of brown.  Off to the glass beading shop we went with the pipes and $18.00 later the pipes were again a nice clean metal color.  A careful application of flat black header paint good to 2000 degrees resulted in some nice looking pipes and the paint truly is "hi temp".  So after nearly a year, the pile of rusty, dirty parts has been completely transformed.

The Beast Lives

Never having wired a bike from scratch before, it took me four days to get all the wiring done.  Tested the wiring last night and I guess the battery was low because today, when we went to start the bike today it wouldn't fire.  Turned out the battery was down to 6 volts.  Swapped in another battery and the bike fired up after three kicks!!  A few oil leaks due to some loose fittings but it appears all is well.  The electric start didn't work although the starter relay was working the night before and now it doesn't energize. But I had it off earlier in the day and probably crossed a wire when I put it back together.  I'll trouble shoot that tomorrow.  Also have a bit of an issue with the brakes but...that's for another day.  The main thing we're happy about is the bike fired up and ran really well.  Not bad for some thing that was just a bunch of dirty parts in the back of a truck less than a year ago.

We're There

Installing clutch and throttle cables on a motorcycle may sound relatively easy but it's not.  At least not on a Harley that is totally different from when it left the factory 44 years ago.  Either cables are too long, tooshort, or they don't fit where they're supposed to.  Same with shift linkage.  But, everything finally went where it should and...except for filling the oil and gas tanks and wiring the bike...we're FINISHED!!  With any luck we should be firing it up in the next few days.

Who's the Old Dude next to that beautiful custom?

Making Progress

After a 10 day hiatus, Curtis and I (mostly Curtis) got back to building "Dusty".  The biggest source of concern and frustration was the primary and electric starter.  Curtis rides only kick start Harleys with open belt primaries and had never tackled a closed chain drive primary with an electric start.  Needless to say it was not one of his favourite activities putting this thing together and nearly put him off motorcycles...at least closed primary Harleys with an electric start.  But he gritted his teeth and pressed on.  It all went together and we think it went together properly.  The manifold, carburetor, air cleaner, coil, voltage regulator, foot controls and exhaust pipes have also been installed.  Next up will be oil lines, clutch cable, throttle, front controls, etc.  Still a ways to go...but the end is in sight.

Pipes, Air cleaner

Primary all together

Chromed and Sparkly

Today we finalized mounting the shocks and modifying the oil tank necessary to clear the primary and the starter.  A finicky job but Curtis mastered it.  Then we picked up the chrome from the chromers and test fit the now chromed pieces onto the bike.  Talk about bike jewellery

 

The dash looks blue because it's reflecting the sky

 

 

Chromed Tail Piece

 

 

Checking the riding position

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Coming Together

The past few days have been spent putting things together.  The engine and transmission are now in the frame as is the front end and rear wheel assembly.  Today we double checked the ride height of the bike with the shocks temporarily attached and determined that the oil tank will have to be notched in order to clear the primary and the starter.  We also finalized the handlebars and set the exhaust pipes in place to check clearance.  We then took the pipes to the U Blast It shop and cleaned them up prior to the application of 3 coats of high temp clear paint.  The bike has turned out exactly as we had planned.

 

Pipes have yet to be cleaned up

 

Not the final handlebars but you get the idea

Engine Completed

I touched up the frame a few days ago as it had suffered a few scratches, etc. after dry fitting various components, welding the oil filter bracket to the frame and a few other mods.  Since the transmission had been previously finished, it was time to finish building the motor.  So, over the past two days Curtis put the motor together.  I mostly watched as he is the Shovelhead "expert" in the family.  Today, the job was done and now it's time to start assembling the bike.

 

Dusty's Motor