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Thread: El Skitzo's Harley Chopper

  1. #281
    Member El Skitzo's Avatar
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    Nice to see you James, and I saw you post on CC about the work you had done. Looks great and I'm glad Tom (Rastas in here) came through with the goods. Unfortunately I didn't make it down there, because I was busy with all this. Kind of got on a roll and didn't want to stop.

  2. #282
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    Cool man, I actually just got my last part today, so I'll hopefully be back down soon, would be cool to check out your bike.

  3. #283
    Member Tbird tracker's Avatar
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    Seat is looking good Skits, gear box troubles over to now I hope. I think I'll be setteling for a pre made seat from Trojan for now.

  4. #284
    Member El Skitzo's Avatar
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    I got a little package in the mail today from Kyle and Tyler at Lowbrow Customs containing all the bungs I need.

    The 4 countersunk bungs accept a 3/8" allen head bolt which ends up recessed in and sitting flush, and will be used at each end of my sissy bar on each side. As you can see in this picture, at the bottom of the sissy bar (at the axle plate) the round bar will be welded to the top of the bungs, and at the top end (on the side of my rear fender) the sissy bar will be welded against the bungs and continue on upwards.

    The 2 threaded bungs also accept 3/8" bolts, the shorter one is 1" in length and will be sunk into the top of the backbone of my frame in front of the seat and be used to mount the rear of my new gas tank. I would have prefered that one to be more like 3/4" in length so I might cut it shorter if I need to run my wiring up through the backbone. The longer bung is 1-1/2" long as I was going to use it for the front mount for my seat, but since placing the order I have come up with a different idea for mounting the front of the seat which lets it sit lower down on the frame and I probably won't need this bung.

    Not many ducks left to get in a row before we head to the workshop...


  5. #285
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    Awesome that they came, what's you're idea for the front of the seat?

  6. #286
    Member El Skitzo's Avatar
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    Quote Originally Posted by Spew View Post
    what's you're idea for the front of the seat?
    Easier if I explain it to you on Sunday in person that type something up

  7. #287
    Member shovelhead's Avatar
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    el skitzo, great to hear ya got ur gear box sorted.. do ya want to work on my my shovel? ha ha ha i dont touch it just wipe off the oil and top up and ride.
    sounds like ur making head way with fab work.. pm me later about ur paint work got an offer for ya to get it all done sooner.. i want to see it all done for
    summer ok...

  8. #288
    Member El Skitzo's Avatar
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    As soon as the rear fender has been remounted I'll be bringing it to you for body work, and probably the gas tank for the mods it needs before mounting. So hopefully I'll catch up with you in the next month or so

  9. #289
    Member El Skitzo's Avatar
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    I just realised this morning that there was one more bracket I needed to make for the rear fender remount to save time making one in the workshop. That is the bracket that will be bolted to the rear of the transmission plate and will be welded to the lower fender strap I made previously. You can see it here sitting in place, and now get a better idea of what I'm trying to do with this mount. Obviously it's waaaaaay to long at the moment, but we'll cut it down to size once we know the final dimensions.




    The interesting thing about making this piece and its a neat little tip when you're making your own stuff, and that is to know the limitations of what you are able to make with the tools you have and think outside the box to work around those limitations. In this case I knew for a fact that there was no way known I could put a nice neat and very tight 90 degree bend in 6mm thick flat bar using just a bench vice and a hammer, you need specialist bending equipment for that, which of course I don't have.

    The solution? Find a piece of metal the size you need with the bend already in it and make your part from that. In my case I went to Bunnings and found this pergola bracket made from 6mm plate which only cost me $4.30.




    Then it was just a case of spending a couple of hours of my time cutting out the shape I needed, drilling the 3/8" hole in it and cleaning up all the edges. I've saved myself countless hours of frustration and wasted material trying to put a bend in some flat bar that I'd never be able to do...


  10. #290
    Member LabRat's Avatar
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    Quack , Quack ... Good thinkin 99 .

    I want to see that sissy bar at least at the same height as the bars ....
    Things I see and places I go - http://www.flickr.com/photos/53061157@N04/

  11. #291
    Member El Skitzo's Avatar
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    One of the last things to organise before hitting the workshop was all the fasteners we'll be needing, so made a stop in at West Coast Fasteners in Balcatta to collect on my long shopping list.

    The key thing here is consistency as at the moment between my rear fender and seat there are 5 different bolt sizes holding the two on and who knows how many other sizes holding the fuel tanks on. Everything you see here is now 3/8" UNC which will cover mounting my sissy bar, rear fender, seat and rear gas tank mount.

    I have 1 extra of each bolt I need to allow for screwing at least one up at some point, with everything shown above the white line being stainless steel. Only 1 bolt is mild steel as that will become a mounting stud under the front of my seat pan so will need to be welded in place. All nuts are nylocks for final mounting, but I've got plenty of regular mild steel nuts for fabrication as we'll probably be bolting everything up and pulling it back down again numerous times. I'm only prepared to resuse nylock nuts 2-3 times so I didn't want to waste them during mockup and fab.

    I think that was the last duck to get in a row, so hopefully the next pictures should more interesting as we finally start making some real progress, and after 15 pages of fluff it will be about bloody time!


  12. #292
    Member El Skitzo's Avatar
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    If you're still unsure of how these counter sunk bungs fit into the whole sissy bar deal, this picture should explain it pretty well now that I've mounted them to each side of the rear fender. The round bar will just sit against the side of the top bungs and then be TIG welded together. A bit neater look than just having a flat metal tab with a hex head bolt through it like was commonly done in the past. I ran out of time and beer to drill the holes in the axle plates for the bottom mounts so I'll do that later in the week.

    In better news I can confirm that Rastas has agreed to come on board with this project and the bike is booked in 2 weeks from now to start all the welding work to get this rear end make over done


  13. #293
    Member Tbird tracker's Avatar
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    Awsom news Skitz, looking forward to some real old school style.

  14. #294
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    Awesome. Tom is a great dude.

  15. #295
    Member El Skitzo's Avatar
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    Finally found the time to drill the last holes, being for the bottom mount for the sissy bar in the axle plates. You can see here the countersunk bung bolted in place, and what looks like the shape of the axle plate designed to accomodate for it. That's because it was, if you buy one of these Santee rigid frames new the axle plates are designed and already drilled with holes to mount a sissy bar. In my case the original builder of this bike must have simply welded them up after they decided they weren't going to use them.


  16. #296
    Member El Skitzo's Avatar
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    Delivered the bike to Rastas' place today, got it up on the workbench and you can see here I've stripped the rear end down to just the frame ready to make a start.

    This is the first time I've seen the rear end without those god aweful softail style rear fender struts, and it was an absolute joy to remove and bin them!


  17. #297
    Member El Skitzo's Avatar
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    Before we start the fab work on Tuesday we first need to fix up what has been left behind.

    The green arrows show all the holes the previous owners have drilled into the frame and tapped to mount previous seats. All these will be filled and ground back to being round. The outer most holes where the seat springs were, are drilled through top and bottom, so there's six holes to fill in all.

    The purple arrows show the mounts the rear fender struts were bolted too. These will be cut off the frame rails and carefully ground down to restore these tubes back to being round.


  18. #298
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    Haha sweet as man, bet you're excited as hell.

  19. #299
    Member El Skitzo's Avatar
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    LOL Will probably struggle to get to sleep on Monday night, so might have to hit the piss and knock myself out ;-)

  20. #300
    Member Rastas's Avatar
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    Holes filled, tabs off, ready for tomorrow.
    Id post a pic but im itarded, it keeps saying invalid file. Stupid ifail

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