| Author | Message | ||
     Phelan |
Cross posted with BB&D. It's been a while since I've shared my changes on BadWeb, so I thought I'd bring anyone interested up to speed. Those of you that are friends with me on Facebook have probably seen these. Anyway, so I decided I wanted a very different look for my Uly. I realize that some would say I should have sold this bike and bought a bike closer to my goals instead, but this turned out to be more intimate and cost effective. I picked up a headlight/fairing setup from a KTM 640 Duke II and a flexiglass front fender to start the most obvious changes. The fender and fairing are painted with Rustoleum 2x Ultra Cover rattlecan paint, but with proper prep work, several layers on black and clear, and a good cut and buff, they came out fantastic IMO. I built my own brackets and moved around everything behind the fairing to get it to fit. I still may change up the top mount as well, to make a better assembly/disassembly process for the fairing and dash, which I need to build a mount for still as well. I changed to a Kick Ash airbox cover, which I ordered new from Surdyke, as it ties into the new color scheme I have planned, which won't include blue anymore. I never liked the OEM brake master cylinder and the Pazzo levers weren't my preference, so I switched to a Nissin radial master cylinder, a Yamaha clutch perch, and ASV shorty levers. I modded both perches and hardware a bit to fit the OEM handguards as well, though those will be modified later. I also sectioned the perch a bit to reuse the dial cable tensioner, for more finite adjustment. The bike is just starting to take shape, but there is still much to do cosmetically. I'm going to change out the tail to a short Lightning tail, swap the forks and shock for Lightning Long pieces, modify and/or build new handguards to my plans, and of course paint everything according to my new top secret color scheme. Here's the pictures of the fruit of my labors.           | ||
| Vicenzajay |
Very nice! | ||
| Phelan |
Thanks! | ||
| Newmans3 |
Hey Ross, We've been patiently waiting to see more of your mods. Any updates? | ||
| Phelan |
Hi Michael! I do have updates, but I forgot I had a thread here on the XBoard, sorry about that! Lots of stuff in the works on this build. A few weeks ago, I completely tore the bike down for rebuild. I made due with the tools I have, including this very handy breaker bar.    I don't think this is supposed to be like this...  Then a few days ago, I brought the cases to the shop. Split the cases to replace the output shaft bearing, trans seal, and crank seal, and clean and re seal the cases in the process. In this picture the cases look black- that's actually just 74,000 miles of grime.  Can you tell which one is new and which is the old?  I polished the derby and inspection covers, as well as the muffler strap, while I was at it. All better now  .  Among other changes in the works are 1125 Forks, Lightining long rear shock, carbon fiber RSS, braking front and rear rotors, new tires, different motor work, painted frame and swingarm, shaved top triple tree with Rooke risers, and new color scheme. | ||
| Phelan |
I'll get some more photos this afternoon. It's been a very busy last few months. I was working out of town every other week, as well as working on other projects when home, and tending to my wife, who is 12 weeks pregnant. (Message edited by phelan on March 20, 2016) | ||
| Newmans3 |
Wow, you have been busy. Thanks for the update, wish I had your skills. Hmmmm, I spy half a tuber in the background of that last picture, side project? Or is that Aurora? (Message edited by newmans3 on March 20, 2016) | ||
| Newmans3 |
Oh, and congrats to you and the wife on the pregnancy!!! | ||
| Phelan |
Thanks Mike! The shop is NRHS; that tuber is a customer who wanted his frame powdercoated, among other things like maintenance and motorwork changes. Yesterday was officially my last day at NRHS, and I am forever grateful for my time and experience there. I moved to Fountain, south of Colorado Springs, back in November, and have been staying in Fort Collins every other week to continue working at NRHS in the meantime. I officially start at Pikes Peak Harley Davidson on the 1st of next month. | ||
| Newmans3 |
Big step, good to get experience at a few different places to learn different skills and techniques. Makes you a more valuable asset to your employer, oh and Badweb too! Good luck at the new place! | ||
| Natexlh1000 |
I never saw a rear XB isolator fail. What kind of a sound did it make when it popped? Were you riding it? | ||
| Phelan |
AFAIK it didn't make a sound, just rode really rough. The rubber pucks are captive in the aluminum donut when installed, but the bond they are supposed to have to it was long broken. I think it's just a combination of this bike sitting for 3 years before I bought it, 74,000 miles, and 10-15 motor rotations for performance work. (Message edited by phelan on March 21, 2016) | ||
| Phelan |
Lots of stuffs in and on the way. I received my 2010 LED taillight, my new rear pulley (which is actually the same as my previous), and my new air box decals, which I'm keeping under wraps for the moment. I bought a different FlexiGlass front fender (the one with scoops) and some black brand new 1125CR forks from the EBR garage sale, and I have another exhaust on the way. I apologize that I haven't posted a lot of pics, but I just got back from Florida yesterday in the wee hours of the morning. I was there for a little over a week doing some wrenching on my client's bikes, as well as some site seeing and good eating on the ocean with my wife while we were there. Still shooting for an April 15th completion date. | ||
| Phelan |
Made good progress today. Finally finished modding the firebolt tail to fit the Uly frame, albeit I also drilled and tapped 2 new holes in the frame flats to fit it. I trimmed the undertray a little to fit the extra wiring bulk, and installed my EBR turn signals (same as 2010 Buell) and 2010 XB R/S LED taillight. Gotta pull it back apart for various holes for mounting wiring, ECM, BAS, etc, as well as paint, but at least now that's out of the way. Tomorrow I'll put the top end and cams/cover back on the motor so I can reinstall the frame on the motor for now, so I can move forward with assembly. Hopefully I'll also have time to install the new steering head bearings (tapered roller bearing conversion) and replacement swingarm bearings.    | ||
| Phelan |
And the accent color is....  And yes I'm going to paint the tail lol | ||
| 1313 |
Stryper, FTW!  BTW, WTF is up with BadWeB right now... Or is it just my daytime internet at the homestead is lacking? | ||
| Phelan |
Oooh, that's actually a great idea for a new name lol. That or Batman haha. | ||
| Ceejay |
ifnya paint the airbox the same color as the tail it'd look damn sharp with those bright decals... neighbor want to come off of that 68? | ||
| Phelan |
The tail will be painted black, but first I'm going to mold the rear cowl into it to make a true solo tail. The neighbor has had that car for almost 30 years (since high school). She'll never sell it. | ||
| Phelan |
I did get the motor reassembled. I got further along than this picture but I forgot to take pics. I was excited and eager to try out DK Customs rocker lockers, but upon reassembling the motor, I realized that I forgot to order them. Not wanting to wait to order some in, I made my own out of some .015" steel. So I should hear a bit less clatter in the top end  .  | ||
| Phelan |
Gettin' beastly! New 1125 CR forks!  | ||
| Phelan |
Movin' right along! Here I got the swingarm, oil lines, and various bits mounted.  Then I bolted the frame and subframe onto the motor, and after this pic I bolted the rear shock as well. Normally you would want the exhaust mounted before attaching the frame, but I won't get the exhaust for another week or so, and I want to make this a roller. I can do a simple motor rotation to install the exhaust later.  Next, I moved to the front end. One of the pieces I've wanted to use for a while were these Rooke Risers. I cut the lower handlebar clamps off the top tree a while back, and today I filled in the original clutch cable guide hole and drilled 1/2" holes to mount the Rooke Risers.  These risers were made originally for Yamaha cruisers with 1 1/4" fatbars that tapered to 1". Since my OSX One fatbar is only 1 1/8" (standard oversize for 7/8" controls), I made shims out of some perforated steel tubing I had and I glued them in place to simplify installation.  Here's a mock up of the trees and risers.  And what's this?? We have a roller! I installed the new CR forks, put a front tire on the wheel, and mounted it up so the bike can almost stand on its own (still waiting on the SS kickstand). After this pic I also installed the front brake setup with new ceramic pads. I may source a shorter brake line, as the stock Uly brake line is now about 8" too long between the shorter suspension and shorter, straighter handlebars. The clutch cable is a little long, but plenty useable. Really excited to see this coming together.  | ||
| Ducbsa |
Pretty classy having matching jack stands!  | ||
| Phelan |
And jack!  | ||
| Brother_in_buells |
Looking good! ,what kind of paint is the yellow? And did you had to heat and bent the xbr subframe or was there some welding involved to? Because it's only about 7mm on both sides in difference between the early and later frames. | ||
| Phelan |
This is not just a later frame, but a long model frame as well. The bolt spacing was way different. I bent the subframe top rails out and down to bolt on, but then realized the top two were about 3/8" too long for the bodywork to line up right. Rather than cut and weld the top rails, I extended the flats on the frame and drilled two new holes to mount it 3/8" deeper to get the bodywork to line up properly. | ||
| Phelan |
I am so close now. I have a new name picked out, and want to keep the rest under wraps for now. I should receive the exhaust and last few bits next week. I'm going to great a new thread when I do complete it, and link it here. Thanks for watching . | ||
| Phelan |
Things are moving slower than I'd like, because of various reasons- job, weather, later shipping on the exhaust, etc. But if I somehow manage to get out of jury duty tomorrow, I should be able to get it running tomorrow. In the meantime, here's a sneak peak...  | ||
| Brother_in_buells |
Looking good there! Are you gonna use that flimsy band clamp that came with the muffler for the rear or using the buell ones!? I upgraded it like this,  Bent two strips of stainless in the same radius as the stock muffler and tack them in place with the muffler mounted how it should and weld them on both sides. This way the muffler fits rock solid and you are not getting problems with worn out headers because of engine vibes. | ||
| Phelan |
Nice, I wouldn't have thought of something like that, but it makes perfect sense. I'm using the Buell clamps. | ||
| Brother_in_buells |
so like to see any updates!? | ||
| Phelan |
Been a busy few weeks with no time for updates. Right after the above pic, the rear exhaust stud broke so off came the head. Got that repaired but the following weekend I drove to Phoenix to buy half a Ulysses. Last weekend I only had 1 day off, so this is my first full weekend without other stuff going on. Gonna wrench on it today and tomorrow and see where I get. | ||
| Phelan |
Starting to look like a bike again! Still lots to do, but so much closer now!   I even got this to match  | ||
| Brother_in_buells |
That looks really good! That ktm front fairing fits it perfect to! |
