And it begins.

[Dennman]

Been dreading this redo for a few years now.That damn deer made it a necessity now.I remember the pain of getting it all spaced and assembled years ago.Got all the spacing for the windshield/wind delectors and lights recorded now.Got a few more brackets bent that I didn't notice before.Gonna be a busy winter.

[sunnydog]

Godspeed with your project Denn, hope ya get into it and hit that zone where you can extract some enjoyment from the process...that meditative state  

[sunnydog]

Btw I think the batwing'll look killer on there

[Big Dave]

we will be able to pick each others grey matter , im sure ill have lots of questions .

Dave

[Dennman]

Godspeed with your project Denn, hope ya get into it and hit that zone where you can extract some enjoyment from the process...that meditative state  

Meditative state..ah yes! When I finally get contorted, between the scoot and the shelving,to work on the clutch and realize I don't have the tools I need.Cursing and grunting as I try to crawl back out on my toes and elbows.
Gotta redo my rear chain idler and swap rubber on the rear wheel.getting the wheel off is always a joy.
Front work won't be too bad.Lotsa room there.

[Dennman]

Btw I think the batwing'll look killer on there

After I finally get it painted ,I'll get it positioned where I want it.Then,in order to get the scoot outa the shed, I'll have to remove it and reinstall in the yard.

[Dennman]

we will be able to pick each others grey matter , im sure ill have lots of questions .

Dave

Pick away.I'll be here.

[Dennman]

Forgot how complicated the wiring to the spots and signals is that I have on there.They came off a later evo ,I believe.Just getting the spots and signals off the brackets requires a headlight removal and plastic multi connectors pulled apart.Labelled all wires beforehand.Even then the spot connectors have to have the plastic end removed to get the wire through the hollow mounting stud and harness sheathing.I have a set of shovel spots now,courtesy of Alex in Greenwood,to put on.The plug-in ends are a different size so I'm hopein that I can get the ends of the others off without distorting them.
 Working on straightening and reinforcing the cracked wind deflectors.Gotta make a run to town for more stainless #6 phillips and nylocs.
 Spot brackets need a wee tweak too.Tryin not to bugger the chrome too badly. Usein a heavy rubber "Gray' mallet w/ a block of nylon as an anvil.The worst one turned out not too bad.

[sunnydog]

Fuckin' electricity is the devil, but apparently its useful!!
Ever thought of mounting a machine gun on the prow to mow down the bambi's as they appear in the shooting gallery/visual frame?
I wired in my signals yesterday, went and got the wife to show-off that I actually wired something myself...when she came to the garage I hit the left signal button and the right signal came on...oh well comme ci, comme ca...

[Dennman]

Just change the bulbs left to right .That should fix it.   

Machine gun...? With my luck I'd drop the bambi dead in front of me and I'd be airborn.Did that once on a speed bump doin ~45.

Twas night and I was in a hurry to get home.Hot chick was comin over for some post bar activity.It was all cool as hell watching the big spray of sparks below me til I realized it was the scoot below me and I was sailing along with it about 5 ft. in the air.And then I landed ....one knee bounce and I was standin lookin back at the scoot on it's side doin the slowest idle that i've ever heard. Stood it up ,jump on ......no shifter or headlight..No problem...Checked around for bits and pieces.Maglight in the mouth,throttle up,jam it into first and shift on the fly.Came back the next day to check out my flight path and for anything I'd missed in the dark.

Don't really want the experience again.

[Dennman]

I knew it would be finacky but Hey Zeus Crisp!!!  

The spot lights both go into a male plastic quick connect that plugs into one hooked to the panel under the nacelle.

I managed to get the crimp on the wire cover open but the one on the wire was just too tight.Managed to spread it and scrape out as much copper wire as I could.The shovel spots have a thicker lead than the fubared ones.Jammed the new spot wire into the spreaded crimp and soldered it.I don't have too much faith in it holding.If it fails I'll just make up my own 2-1 quick connector.

The HD ones are just too neat and compact otherwise I'd just clip them off and find something suitable.

[sunnydog]

fuck around fuck around pretty soon you'll SEE around...that's my light wiring motto!

[Dennman]

Got the spots and signals back on the brackets.Had to cut a slot, for the wire to hang out, in a deep socket (used a 14 mm) in order to tighten the nyloc holdin the spot to the bracket.Got the nacelle off after disconnecting the spot switch and its indicator lamp.
 Realized    that I'll have to unplug all the wiring behind the nacelle in order to service the neck bearings.  Now that could be a real chore/headache w/ all those little spade connectors in the terminal block.Always manage to break one off no matter how careful I am.At least I have all the wires coded, w/ tape, as to where they go in the different circuits of the block.
 Think I can get away with just unboltin the handlebar clamp from the top tree.Then pad the tanks and lay the bars back there.
 Tomorrow! 

[sunnydog]

Yeah dealing w everything in the nacelle is fun times...I've had my bars off 5 or 6 times in the last couple years and it's tricky just to get at them riser bolts inside there...think I'll prolly make a special wrench next time I do that....yep I just lay the bars on the tank too, apes are actually nice in this situation cause most everything hangs down and out of the way!
Labelling everything is smart. My wiring inside nacelle is a real snarl, troubleshooting is tough...I've spent a lot of time chasing issues in there, it's like Pandora's box.
Just think, the RoadSlayer will be tiptop for spring riding soon....then what are ya gonna work on??  

[Dennman]

Just think, the RoadSlayer will be tiptop for spring riding soon....then what are ya gonna work on??  

After the front end I have an issue w/ the rear head.The back two head bolts will not hold torque.Wonderin if that spun wrist pin at the end of last year let the piston come high enough to pull those two head inserts.Fought it all last year.Bike would start to backfire at low RPM/speed.Knew it was time to tighten those bolts again.Finally ended up changin the intermediate jet from the 29.5 to a 31.Then it would be alright for a longer period of time before tightenin again.

Hope they're not but if so, i'll be putting my stock rear head on that has been reworked for the B cam and big bore barrels.Ran that way a couple years ago only it was the front head on my previous set of S&S super stock heads.Didn't have any noticable difference in performance.

[Dennman]

Whale Oil Beef Hooked!






All my wire tags have seen some road dirt and weather.Had to pull the wires one by one and relabel.
 


Took me most of the afternoon to do it.Once the sun went down ,it got COLD.Rushed to finish labellin and get the bars laid back.Earlier I put foam water pipe insulation on them to try and save some tank paint damage.



Tomorrow................SPROING!!!    

[jmac]

I,m working on a little chopper doing the wireing..So it can pass the BC inspection.Can,t post pic,s I mounted a blue hybeem indacater lite in the head light bucket then took a skull nut and bored out the thread,s drilled the eye,s out and glued it over the lite look,s fucken cool .jmac

[Dennman]

I,m working on a little chopper doing the wireing..So it can pass the BC inspection.Can,t post pic,s I mounted a blue hybeem indacater lite in the head light bucket then took a skull nut and bored out the thread,s drilled the eye,s out and glued it over the lite look,s fucken cool .jmac

Sounds cool jmac.Is that one of those skulls like the licence plate mountin ones?

And yer slippin or you're no longer confused. 

[sunnydog]

Lol yeah Jmac where's that famous confused icon?

Damn Dennman that's a snarl of wiring...  

[jmac]

I,m confused really:scratch: jmac

[Dennman]

Lol yeah Jmac where's that famous confused icon?

Damn Dennman that's a snarl of wiring...  

As I was pullin it apart ,I had flashbacks of putting all the wires in that terminal block.Can't just take one sub-harness (ie right/left bar or main to switch and rear lights) and plug it in then move to the next sub.Ya gotta work your way across the bottom and then up row after row.Otherwise the wires get in the way of reading which circuit is which on the block.

[sunnydog]

I have one favorite thing about wiring projects.....
THE END of the job!! And I'm usually lookin about like this in a dark garage  

[Dennman]

I have one favorite thing about wiring projects.....
THE END of the job!!  And I'm usually lookin about like this in a dark garage  

                                                     

                   

                                 ^
 Better that than this  ^^^   or   in the light.

[kootenai]

sometimes it goes..        

[sunnydog]

sometimes it goes..        

That's a typical day round here Koot  

[Dennman]

Fuckin Computer ate my Status update.

So Drained legs.Got almost 20 Oz. so didn't loose much.
Dropped the tubes w/ sliders after pullin off the Fender.My last JB weld glue in bolt was TIGHT.Left some good JB threads in the leg.  
 
Pulled the trees and checked the bearing races.Visible bearing wear in both Races.The bottom has some odd wear on the top front of the race.Marks similar to the others but heavier and they don't cross the total width of the race surface.Could be from the deer slam.

Top Race



Bottom Race



These have been in since 2008 so approx. 25,000+ mi. and a deer. Top bearing is Mexican and the bottom is possibly Japanese.Bought a set one time and they were mixed,so this could be them.
Notice the holes under the inner race edges.There are 2 in each cup to facilitate removing the races w/ a punch.Drift out the cups and then punch out the races
Will be lookin for 2 sets in town.Hope I get a matched set this time.

As it sits now.

[Dennman]

Found a little time today to drift out the neck cups.To drive out the races I had to make up a punch to fit the holes in the cups.A few taps side to side, using a 1 1/4 " socket as an anvil, and the races popped out.Now to get that bottom bearing off the spindle.Tried a small bent chisel but not much success.Will get out the dremel and cut the bugger to get a slot to spred it and then pop it off .

Edit to add:Surprise,surprise surprise!! The bottom race was American made so the bearing probably is too.That one has probably been on there even longer than the top.

[sunnydog]

Damn that's alotta work eh?? Making progress though...so how much damage from the deer impact?

[Dennman]

Damn that's alotta work eh??  Making progress though...so how much damage from the deer impact?

Front end: Dinted -fender
                         -cowbell
                         -Right tank,twoney size
                         -braided front brake line flattened 1/2 way by tank pinch
                         -left spot lamp and broke off
                         -windshield pushed back and brackets tweeked
         Stripped out-fender bolt holes in legs
         Road rashed-front master cylinder
                         -hand clutch bracket & cable
                         -windshield brace bolts
                         -crash bars
                         -floorboards
                         -front bumper rubber and tip
Rear end:Road rashed-tour pack top right corner/edge
                             -right saddlebag small puncture
                             -all bag rail acorns ground to hex heads
                             -front bag rail brackets bent outa shape w/ resulting offset to one side of the whole assembly
                             -Outer primary ground and recracked below derby cover                   
Personal gear:Road rashed-Large gear bag handle wore off and end holed
                                   -cargo net shredded
                                   -rain gear left arm and left hip area shredded
                                   -hole in leather jacket,hoodie,long sleeve shirt left elbow
                                   -Small fingernail size scar on left elbow 
Probably a few more hidden cracks but other than the fender bolt holes and leaky outer primary ,still rideable.

[sunnydog]

Well that's substantial!!
What else are ya still lookin for in your fix list?
Dawg

[Dennman]

Well that's substantial!!
What else are ya still lookin for in your fix list?
Dawg

I have everything that I need for the replacements and the JB Weld will fix the broken.
Oh the joys of stockpiling parts from swaps when I don't need them at the time.
If I see something shovel and it'll fit (and the price is right),It's comin home.

[sunnydog]

Good to hear Denn...I don't know anybody rides a Shovel far as you...I'm thinkin that's reason enough to stockpile the way ya do  

[Dennman]

Good to hear Denn...I don't know anybody rides a Shovel far as you...I'm thinkin that's reason enough to stockpile the way ya do  

I regret the one time a fella had all his takeoff shovel parts and alot of brand new OEM parts.Picked up a few things there.A rollin papered chassis, missin only the motor, for $1000.Wish I'd had the cash for that.

[sunnydog]

Yeah I never seem to have the salad for deals like that...oh well I'm savin up for a touring rig now, hope to have one by early summer...we shall see

[jmac]

We have a ton of shovel part,s here at the shop.I,m currently dealing on a 1980 fl but it,s fucked.I,m thinking the only thing any good on it is the tittle:scratch: jmac

[sunnydog]

Good to hear Denn...I don't know anybody rides a Shovel far as you AND JMAC!!!...I'm thinkin that's reason enough to stockpile the way ya do  

[Dennman]

Good to hear Denn...I don't know anybody rides a Shovel far as you AND JMAC!!!...I'm thinkin that's reason enough to stockpile the way ya do  

Glad you ammended that.Meant to do that last night.Johnny did alot less wrenchin on his '77 than i did to do the miles.

[sunnydog]

Like they say, "never piss off the Chef"  

[Dennman]

 Was gonna go to town and buy one of those ball-joint forks (?).Decided to take an old 3/4" chisel and do a little grinder massage on it.Ground it down to a long tapered chisel and fine tuned it w/ a file. BF'nH and the chisel had that bearing off in no time atall.
 Managed to tap the cupped dust shield back into a usable piece.
 Put a skim of Krylon Rust Paint on the trees to cover the chipped areas and makem L  K  purty again.Can't see much of em under the nacelle but what is visible is all gloss black.   "I see a chipped tree and I want it painted black!"

[sunnydog]

Wow Denn, tap into that creative vein ya got goin on and don't let it end!!  Legendary display of woodshed ingenuity, emoticon usage, and classic rock references, you had me at LMAO.

[Sponsored content]