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Old 04-25-2020, 06:38 AM   #1
Dutch Dennoz
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Default A lifetime project

So as i mentioned in my introduction i own a bike and i own some creativity and i happen to work in a machine shop.
In my humble opinion the shovelhead is a diamond in the rough with some oversized corners but thats whats customizing is all about.
I already done a lot of modifications visible and non visible but most of the time when i am done at the rear i start over again from the front.
My current project is to replace the chunky alloy primary by the pressed tin type.
When the inner primary arrived i was not impressed by the ďfit from any distanceĒ tolerances on it, it even came with a note that said not to give a shit about the chrome quality but thats not an concern at all.
because i am not all about the looks but also want modifications to last i took action and machined a bracket that ensures the fixed relations between the engine and gearbox as well as remaining the bearring support.
The inner primary only functions as a shiny cover as long as the chrome last.
Make note of the 2 countersunk tapped holes on the back, they are there in precaution for another modification.
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Old 04-25-2020, 10:43 AM   #2
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Default Re: A lifetime project

Nice work! Welcome to the JJ.
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Old 04-26-2020, 03:19 AM   #3
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Default Re: A lifetime project

very nice
crack on.
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Old 04-26-2020, 05:49 AM   #4
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Looks great! welcome!
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Old 05-15-2020, 05:14 PM   #5
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Back again! For who ever was curious.
The project evolves on a low paste but is going forward.
As a youngster i used to ride honda ss50ís so i was a bit spoiled with smooth cruisin, i think my dad sold me a pretty worn down machine so the quest for upgrades started right away. I am guessing clutch issues on a shovelhead is not an unknown road to many of you.
I recall the first trick was that plastic ramjet clutch retainer, not satisfied. Following steps over time were ĎHeavy dutyí pressure plate, 10stud hub, big chunky diaphragm , panhead style throwout bearring and ending with a home made Adjustment screw with a bearring and a pocket to centre the Pushrod. Followed by a BDL 8mm belt set up.
Still i felt there was more to gain and that is what keeps me busy on the background. I own the bike for over 20 years now so this describes the process in a nutshell.
I bought a 5 speed tranny cover and copied that part that holds the release ramp lever construction, with some grinding and welding i was able to put it in a 4 speed kick cover , it worked quite okay but i was not happy with the position of the clutch cable...i think it was a bit due to the combination of my baker 6into4 and the exhaust pipe.
The next thing i came up with was as seen on the sportsters , the ramp lever on the left side .
so i blocked the main shaft and started some milling turning grinding welding activities and i mounted a sheet metal construction in place of the derby cover (late shovel tin outer primary mash up cover).
And guess what ....my life was still not complete. It operates smooth but Again the position of the cable bothered me a bit and the weak starter engine construction made it a kick only which i got used to over time.
So now i came to that part where I decided to get rid of the chunky inner primary and my starter gear and do some serious improvements. I had to narrow down some bdl parts as well by 1/4 inch but now i am even able to cover up the clutch cable inside the primary. It is not like i am never satistfied but when i have a plan i want it to come together.
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Old 05-15-2020, 11:00 PM   #6
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Slick.
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Old 05-21-2020, 05:13 AM   #7
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Unfortunately i had to leave some of my clutch parts at work and we have some kind of holiday break...so what to do now. I cleaned up the tiny cave and gave the bike a rub, i have to admid i am not the knight with the shiny armour but i kind of like the raw finish. I think there are some parts worth of sharing , some with not really a purpose of machining them but just for the fun of it.

High/low switch
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Old 05-21-2020, 05:14 AM   #8
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Just because
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Old 05-21-2020, 05:15 AM   #9
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Airhorn
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Old 05-21-2020, 05:18 AM   #10
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Home made invader with a machined hub , i am happy with the result but the next one will be 18inch with the hub in stainless as well.
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Old 05-21-2020, 05:29 AM   #11
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And a tech tip i became from some old guys who have been into harleyís ever since We have been liberated.

Put a nail upside down onto the main valve with a tiny o-ring as a marker , you can exactly tell If your crank bearings get lubed.
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Old 05-21-2020, 06:43 AM   #12
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A Phillips head and a flathead screw on the same points cover?

You're a monster.

Good work. Bike has some real neat bits on it. That hub looks like a ton of work.
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Old 05-21-2020, 07:05 AM   #13
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Quote:
Originally Posted by govmule84 View Post
A Phillips head and a flathead screw on the same points cover?

You're a monster.

Good work. Bike has some real neat bits on it. That hub looks like a ton of work.
Damn ...sharp notice , i will have to fix that before jp tunes in...which one do you prefer me to keep? The flat or the phillips.

Machining the hub costed me at about 8 hours i guess ...it was mainly conventional machining, welding it together and straightening it out another 4 hours and the TLC on the finish i did not kept track of.
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Old 05-21-2020, 02:38 PM   #14
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Please understand that I speak from the deepest depths of ignorance. But I can't decide whether your homemade wheel looks both beautiful and like a deathtrap, or just beautiful. The best I can do is to infer, from the quality of your work elsewhere on the bike, that the wheel is probably safer than any genuine Invader ever was. Which, if I understand correctly, doesn't set the bar too high; but still, real nice work. Thanks for the show & tell.
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Old 05-21-2020, 03:01 PM   #15
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Thanks and No worries Ratso , All opnions are welcome , i was not very charmed by the ‘original’ construction of a invader wheel as well and that is why i decided to machine a hub with pockets at about 1 inch deep to put the tubes in, i really had to press them in and after they where in place i machined the assembly to the rim diameter. The chunck of lead on it was only needed after avon s&m was mounted.
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Old 05-22-2020, 06:33 AM   #16
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So , as you all might know, all those parts together make it a motorcycle.
I was bored anyway so i cleaned our 10 square meter garden and took some pictures , it is really not easy to find the right angle with your back against the wall. This place is really sardine town but i am glad we Found a spot with a small shet with a back entry. Once the clutch is done i will putt some energy in smoothening up some brackets and misc small parts , and then since the starter engine is gone i can change the oil tank to follow the profile of the frame pipes as seen from above....and after that a crazy frank inspired fender. And damn whatís next.
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Old 05-22-2020, 07:20 AM   #17
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Quote:
Originally Posted by Dutch Dennoz View Post
Just because
Oh my god!!! what's wrong with you??? get those screws the same type!!
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Old 05-22-2020, 08:06 AM   #18
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Quote:
Originally Posted by [JP] View Post
Oh my god!!! what's wrong with you??? get those screws the same type!!
Please zoom in on it in my latest post.
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Old 05-22-2020, 11:35 AM   #19
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Quote:
Originally Posted by Dutch Dennoz View Post
Please zoom in on it in my latest post.
I shouldn't have!!
i noticed the screws are ok now... but... but!! the cable tie holding that rubber boot on the fork!! it's wonky!! Hhahahahaha
this is getting silly now. I need help.
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Old 05-22-2020, 12:19 PM   #20
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The dog ate all my fork boot clamps

Something for the shortlist ........obrigado!
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Old 05-22-2020, 08:40 PM   #21
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Ah, fuck, I liked the crazy screws.
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Old 05-30-2020, 06:59 AM   #22
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I am not getting dizzy for the worlds fastest improvements but it’s slowly getting somewhere.
An important issue for me was to get the clutch actuator covered up , in that I succeeded , but i wont call it a wrap yet.
The bended pipe on the end ofcourse causes a bit of extra wear and friction, and dispite it works and won’t brake down in an instand i Will engineer it a bit more further on with a 3 point lever To reduce the wear and straighten out the cable.
At least Now i know how much room there’s left between the clutch basket, cable and primary cover...not much to nothing.
A next resort could be the BDL bbp diaphragm pressure plate which use an half inch shorter shoulder bolts so there’s more space available but i think i will Pull this off (typical for a clutch)
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Old 06-02-2020, 10:14 AM   #23
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you're doing really cool stuff there!
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Old 06-02-2020, 11:34 AM   #24
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Thanks a lot , i am kind of cracking my head on it at this stage.
Sometimes thinking inside the box is even more of a challenge.
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Old 06-05-2020, 05:12 PM   #25
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So......
I took a lot of time this week to explore some options , both of them stranded half way the fabrication when i was able to bite the parts like a monkey and realized some other disadvantages might come along. Some old fashioned grinding and welding..and grinding did the job at the end , a Nylatron insert provides the guide , the feel does not differ from a straight cable now.
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Old 06-05-2020, 05:57 PM   #26
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Elegant.
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Old 06-19-2020, 07:42 AM   #27
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Not a fan of the "jailhouse bars" but otherwise I love the look of your bike.
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Old 06-19-2020, 11:33 AM   #28
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Thanks a lot .
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Old 06-27-2020, 05:06 AM   #29
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I like that a lot. Is that a modified Sportster/Superglide headlamp mount with the skirts?
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Old 06-27-2020, 11:15 AM   #30
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I like that a lot. Is that a modified Sportster/Superglide headlamp mount with the skirts?
Exactly, just that sheet metal cover with some eyebrows and sideburns.
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Old 06-27-2020, 11:39 AM   #31
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I still have a lot of work ahead because one thing always leads to another, but for now they are small stuff like cleaning up the coil bracket and floorboard mounts, hiding the rear brake master cylinder and stuf like that....i had spend some time on fabricating an Oil filter adapter inside the tin primary with an assembled height of only 69 mm , but the available space turned out to be 65 mm.
Starting al over again with a flatter filter...and offcourse the diameter needs to be a few mill bigger. The next in sight Mod will be the smaller profile oil tank and we will see whatís next. Cpt fred got me inspired with the hammerite and owatrol because i never thought of the combination before .
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Old 06-28-2020, 06:49 AM   #32
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hey Dutch , I basically did the same mod on my 65 kick only . I used after market tin primaries . Had to heavily modify the inner for the bearing support , and grind the ribs off the bearing support to obtain a flat surface for the inner primary to lay on . The hardest part of the project was getting the belt on with the tranny being non adjustable after it was bolted solid to the inner primary ... but you cant beat the look of tin primaries !
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Old 06-28-2020, 08:23 AM   #33
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Question, are your coils wired in series, or parallel?


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Old 06-28-2020, 12:25 PM   #34
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Agreed on the looks of the tin primary , it rewards all the effort...even with the thai chrome on it., i wired my coils parallel Medyo.
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Old 06-29-2020, 06:16 PM   #35
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Your invader style rim looks awesome. Nice work.
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Old 07-12-2020, 03:23 AM   #36
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Every year just a few weeks before the holidays suddenly comes to mind the changes i have to do to our Van just to make it a bit more comfy for a short trip.
So there is not much time left for the bike but that donít mean i forget all about it, i was overthinking some sort of cover for the ignition coils because I really think they are hideous no matter what shape or size they have.
I found something in my old manís garage that turned out to be some sort of vintage bathroom refreshing unit but itís just what i needed.
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Old 09-13-2020, 04:00 AM   #37
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I am not really progressing at the speed of light but it is still an upslope.
The back of my head was not satisfied with the idea of a clutch cable in a thight corner so i had to give in a bit again but i am down with the results as it is still about The operating , with some directions of Joe i managed to find an oil filter that meets the specs but still fit in the primary.
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Old 09-13-2020, 04:09 AM   #38
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I ordened the coils and cover and floorboard And some misc stuff and now i am putting the attention to an oiltank that does not force me to sit wide legged on the bike.
I found a vintage dutch moped gas tank that i intend to fit on it...something different i guess....i like the origional color scheme of it so maybe i redo it and mate the rest of the painted parts to it. The tail section will be a subject of change as well again , i posted some parts of it like the queen seat on the local ebay and i allready receieved an offer of 20 euros....mmm must be my lucky day
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Old 09-13-2020, 12:12 PM   #39
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Now and again I get struck by the wild imagination and sheer capability of many JJ contributors. (Then I swallow my tongue and pass out.)

Thanks again for the show & tell, Dutch. Also, thanks for the quote (below). Words of wisdom!
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Old 09-13-2020, 12:26 PM   #40
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Excellent work Dutch, The old primary tins are beautiful, I get the open belt look, but I love them on my bikes! So fully get your point of view!

Coming along super nice!!
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Old 09-13-2020, 01:28 PM   #41
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Thanks a lot [email protected], bite the parts like a monkey!!!
Check one of my tattoos
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Old 09-13-2020, 03:16 PM   #42
Ratso
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Default Re: A lifetime project

Yup!
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Old 09-26-2020, 07:48 AM   #43
Dutch Dennoz
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I was cleaning up some cabinets and i came along an experiment i kind of lost track off.
When the time is right i will proceed it ...or forget about it again.

1 piece o-ring / band style inlet manifold thingies ...why? ....Why not.
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Old 09-30-2020, 10:22 PM   #44
Larry Ritchey
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That sure looks better than the worm drive clamps that came with mine.
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Old 10-01-2020, 11:08 AM   #45
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Quote:
Originally Posted by Larry Ritchey View Post
That sure looks better than the worm drive clamps that came with mine.
Should be band clamps, not worm clamps. I like the t bolt clamps.
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Old 10-15-2020, 02:27 PM   #46
Dutch Dennoz
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I am still busy with the oil tank and behind on my own shedule , i had to order a new lead loading set, but the body file turned out te be in back-order. After a week i recieved the file but they forgot to put the blade in the box....great.
To comfort myself this week i machined a oilpump cover with bottom connections because i donít dislike oilhoses but I donít want them to be too dominant in sight.
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