[Dutch Dennoz]

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 “fit from any distance” 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.

 

[Dutch Dennoz]

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 ss50’s 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 ‘Heavy duty’ 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.

 

[Dutch Dennoz]

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

 

[Dutch Dennoz]

Just because

 

[Dutch Dennoz]

Airhorn

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

And a tech tip i became from some old guys who have been into harley’s 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.

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

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 what’s next.

 

[Dutch Dennoz]

Oh my god!!! what's wrong with you??? get those screws the same type!!

Please zoom in on it in my latest post.

 

[Dutch Dennoz]

The dog ate all my fork boot clamps

Something for the shortlist ........obrigado!

 

[Dutch Dennoz]

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)

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

Thanks a lot .

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

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 what’s next. Cpt fred got me inspired with the hammerite and owatrol because i never thought of the combination before .

 

[Dutch Dennoz]

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.

 

[Dutch Dennoz]

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 don’t 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 man’s garage that turned out to be some sort of vintage bathroom refreshing unit but it’s just what i needed.