Anatomy of a Performance Bike Build Part 2

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Anatomy of a Performance Bike BuildPart 2

• Now this I can work with! This is the frame and
  swing arm from the bike. This will survive with
  very minor changes. I have already moved the rear
  brake master cylinder and lever mount over to the
  left 1/4" so it will miss the trans plate. I may
  modify the swing arm so I can use a 1" rear axle.

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Anatomy of a Performance Bike BuildPart 2

• These are the spoke wheels that are on the way
  out. They will be replaced with lighter wheels
  that allow for a bigger front and rear tires.
• The forks are nice....but, newer 49mm forks would
  be cooler and the weight is about the same. I
  will machine my own trees to mount them.

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Anatomy of a Performance Bike BuildPart 2

• Hmmmmmm? This V-Rod fender might work!

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Anatomy of a Performance Bike BuildPart 2

• This shows the difference in the width of the
  stock tire compared to a 160 X 17. The 17 is a
  radial and is lighter. I may go to a 180. The 180
  tire may be a little heavier than I want to be.

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Anatomy of a Performance Bike BuildPart 2

• OH MY GOD!
• Is that really a custom made TITANIUM axle? Jim's
  pulling no punches here to save weight.

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Anatomy of a Performance Bike BuildPart 2

• Some of you may not realize that Harley will
  only sell a replacement set of cases
• You can't just order a set of engine cases. That
  leaves the after-market as the
• only option for a new set of cases.
• This bike originally had an Evolution engine and
  I want to replace it with a
• Twin Cam. SS sells a set of Twin Cam style cases
  that will bolt into this
• chassis. I don't want to spend that much money
  and that would also be way
• too easy.
• Fortunately I knew someone with a damaged set of
  stock cases that was
• replacing them with a set of the SS Twin Cam
  style cases. This set had some
• issues that I am capable of repairing.
• The flywheels had damaged this set and ruined the
  holes for the sprocket
• shaft and pinion shaft bearings. Repair them and
  I will be ready to go and I
• will spend less money.

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Anatomy of a Performance Bike BuildPart 2

• Here I am boring the hole for the pinion side
  bearing to accept the larger size bearing.
• It was critical to take care and locate this hole
  exactly where it was so the case holes line up
  properly.

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Anatomy of a Performance Bike BuildPart 2

• Here is the finished hole, ready for the larger
  bearing. I left a shoulder on the outside so the
  bearing can't move out towards the cam chest.

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Anatomy of a Performance Bike BuildPart 2

• I  also had to repair the drive side case half. I
  bored the existing hole out to a larger size to
  accept this insert.
• Here I am boring out the inside of the insert. It
  is also critical to bore the inside and outside
  diameter of the insert without removing the piece
  from the lathe. That way, the two bores run true
  to each other. If you bore the hole in the
  original place, the case holes will line up.

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Anatomy of a Performance Bike BuildPart 2

• This is the finished insert. All I have to do is
  heat up the case to expand the hole and drop it
  in. It will be there for good. This insert allows
  me to use the older Timken style bearing.

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Anatomy of a Performance Bike BuildPart 2

• Here is the drive side case with the insert
  installed. All I have to do is drill a couple of
  oil holes and the case is ready for flywheels.