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Harley Sacreligion


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  #1  
Old 09-24-2014, 05:08:39 PM
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Default Harley Sacreligion

Fellow Stakkers,

Today marks the first 'physical' labor done on a project I have been dreaming/planning for too long. I am documenting this project. If this is not offensive to anyone and in the correct place, I will display it here. A brief detail follows:
Full sized 1920's American motorcycle Replica. Not some Hipster motor driven bicycle. I will be making my own crankcases, cylinders, heads, frame, fork legs, fuel tank.
I have always loved Harley JD's, Excelsior, Ace, Clevland . . . AHH who am I kidding, I love them all. My big problem is I can't justify to Mrs. RDub my need for a six figure motorcycle Alas, I have a bunch of old crusty parts doing very little in the barn. One of the things I love ( I suspect this to be true for a lot of you too) about all the early stuff is that the individual designer, craftsman had the ability to leave some of himself with the machine. You know the whole 'if you can dream it you can do it' thing. I one day found myself asking the question, "Why not build it" So, I started educating myself and making a plan. As I said before, today that plan took physical action today. That plan involved doing something "sacreligous". I cut apart a unit construction HD case. I know in the 70's guys would do this to differentiate their bike. Never made much sense to me! Soo. . . That should give enough teaser info. If the consensus is OK. I'll post as the project goes along.
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Old 09-24-2014, 06:14:11 PM
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Default Re: Harley Sacreligion

You can always get one of these like I did... very nice

http://www.timelessmotorcompany.com/home.html
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Old 09-24-2014, 06:19:42 PM
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Default Re: Harley Sacreligion

I am building a bike with one with this engine I picked up and a early harley trans..
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Old 09-24-2014, 06:21:42 PM
Ed Radtke Ed Radtke is offline
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Thumbs up Re: Harley Sacreligion

post away!Bike building is fun and practical{or so I tell myself}.
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Old 09-24-2014, 08:55:33 PM
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Default Re: Harley Sacreligion

Ron,

The timeless machines are very, very nice! However, for the cost, I can build my own machine the way I want. It's the little things like the way Yale cut the cooling fins so when the engine is in the frame, the fins are parallel to the ground.
Your motors are beautiful!!! I could totally build an awesome bike around those. a few problems with tha for me. One, I can't buy one of those for what I can make my own. If I owned either of those, I would want to make the bike as close to original as possible.
Another aspect for me is this; I intend to ride the wheels off this thing. Cannonballers and a rare few excepted, most pre war bikes are impractical to ride and maintain for the mileage I ride each season. As an example, my daily ride is a '48 Pan. My work is 19 miles one way. 17 of those 19 miles are highway. My bike goes 65 mph. I've even had it over 80 mph. My motor is put together well (so far! 23k miles) but I'm not combfartable doing that 4x a week. Last year I put just under 6k on my bike. I wonder how many times I have kicked that machine? Anyways, take away 25 years of technology, I don't think it will become more practical.
So I build my own machine. With neat things like 4 gears. A Starter! I'll keep it hidden I promise! Hardened valve seats. Attainable, inexpensive, modern parts.
My geometry! I'm big boned (FAT).
Plus, I hate to admit this Ron, I'm really shallow. My ego would love to tell anyone who asks, 'Who did this, where did it come from?'. Me. My imagination.
Thanks again for the awesome photo of your motors! I bet you had more than a few ounces of elbow grease to get that case polished so nicely?!
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  #6  
Old 10-04-2014, 08:14:40 PM
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Default Re: Harley Sacreligion

OK, sorry it took so long. That work thing keeps getting in the way. This is the cutting in half of the cases. Nope sorry. I'll have to wait 'til Monday when I can get help. So, the cases are now cut. I have been shaping them so that we can digitize them onto the cnc. I have been doing most of this with small carbide burrs, files and the sawzall. On the primary side case I have removed the primary cover mounting flange. I will plug the oil return screen (among other things) with weld. I will then remove portions of the boss. I have also removed extra casting material that didn't get cut during the initial cut. On the cam side, I have cut off the section where the generator would mount. I have removed the large oil passage that was used to get oil to the primary side of the case. I will be using copper tubing for this. I believe this will be more aesthetically right. I also removed both exhaust lifter bores and bosses. The cam chest when done will be sorta like an upside down triangle with bottom point being rounded. I still have a whole lotta shaping to do to these but, these are starting to show the general idea. Sorry about not having pictures. I promise I'll get them uploaded on Monday.

rodney
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Old 10-06-2014, 10:09:33 AM
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Default Re: Harley Sacreligion

Bothe Side cases before and after 'lopping off' trans side. More pictures and a small story of stupidity. coming momentarily
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Old 10-06-2014, 10:14:55 AM
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Default Re: Harley Sacreligion

This is what the the primary side looks like after improperly supporting in the press. It also would have helped to consult my manual. I would have then been pushing the correct way
I will never make that mistake again At least this case was being sacrificed for a pattern!!
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  #9  
Old 10-06-2014, 10:26:05 AM
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Smile Re: Harley Sacreligion

Iron barrel sporty, no worries! Just hammer that broken aluminum back in there and it's good for a pattern. Good for you tackling a project like this! On the other hand I'm not that ambitious and just push the button on my Ducati and drag the occasional knee on the back roads.

As the cold is here and outdoor activities are now dead for about 6 months, I'm sure the engine will be making noise by February. !
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  #10  
Old 10-06-2014, 11:09:20 AM
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Default Re: Harley Sacreligion

More photos. This shows the removal of the mounting pad/boss for the primary cover. The next picture is the removal of the intake lifter bosses. The timing side also shows the removal of the oil transfer cavity between the two case halves. This will be filled, tapped and plumbed with external Ni/cop line. the last pic shows what still needs to be removed from the primary side. The oil transfer, primary return and primary tensioner boss. More coming.
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Old 10-06-2014, 11:33:20 AM
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Default Re: Harley Sacreligion

Last of the day. I'm supposed to be working.
Here you can see the cams in the chest. The thing I'm holding is the tach drive. This will be replaced by a morris magneto. If you are familiar with mid 70's sporsters you will recognize the #4 exhaust cam. I am starting out with P cams. Depending on the spring rate for the atmospheric valves. We should be close to the right overlap. When thinking about this engine, timing has proven to be the most complex (too much math) to understand. Then even after all the advice from truly smart men and formulas it is still unknown if it will work?! Theorhetically, we are in the ball park. Here is one that required a lot of thinking. . . Did you notice the cams are not positioned in a parrallel line in the case? The pushrods are equal length. How is this? Now I know I left out some information but, I did scratch my head thinking about it for a while.
The other pic is bits and scraps from the cases.

I started to make the cam cover. Yep, cut up another perfectly good HD part.

I am only using my die grinder and dremel right now. When I get everything rough shaped, I will take them to the shop and clean and true on the bridgeport. I only have limited after hours access Then more hand work and on to the cnc.

more coming soon. . .

rodney
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Old 10-06-2014, 11:42:31 AM
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Default Re: Harley Sacreligion

Hey Oldstuff- I better be done by Feb doesn't riding season start after Valentines Day? In reality that would be awesome. I am making the frame for this thing too. . . then the whole sorting it out thing. If I'm lucky it'll get ridden by late season next year.
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Old 10-09-2014, 11:20:53 AM
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Photo Re: Harley Sacreligion

Just a quickie on the frame. These pictures are of a wall hanger bike frame. This is a pre-war HP Evans (Rollfast). I'm using this bike as the basic design for my bike. Obviously, I will need to make many changes to fit my fat a$$, the motor and style I want. The other pictures are the sandblasted '75 Sportster frame. This frame was chopped probably sometime in the mid to late 80's. I'm guessing that based on the style of the bike and parts that were on it.
I am currently debating selling this frame as a rolling chassis. With all the changes to be made, I may be better off just starting from scratch. The only reason I am hesitant is This frame is straight and true. I can modify this one and keep it true. I'm not as confident of my jig on a complete build. I know my thinking is flawed here. If the jig is good enough to do the one it should be good enough for the other. Just one of those quirky things.
I'm hoping to work on the motor cases this weekend. My big problem is I just bought a really cool two push rod Jacobsen that I want to play with this weekend. I am also in the middle of a restoration of an old Lombard saw which is close to being done. No rest for the wicked. Or in our case the 'afflicted'.
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Old 10-10-2014, 09:23:36 PM
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Default Re: Harley Sacreligion

Perhaps of interest:



Whatever style you choose; GO FOR IT!
Doc
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Old 10-13-2014, 08:38:46 PM
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Default Re: Harley Sacreligion

I managed to not mess with the Jacobsen this weekend! I still didn't get much done on this bike. A friend and I went on a hunt for junk based on stuff we had been told. We left at noon. I told my wife I'd be home by dark. We found the place. This guy has been scrapping for 40 years according to him. Some good stuff if you get past the junk. I called my wife at dark to tell her I was heading for home. I was an hour and a half away. Needless to say, I didn't get a lot of shop time. I did manage to get the cams and pinion set with bushings attached. From there, I made some cardboard and tape enclosures. I will make patterns from this mock-up. Then I will cut out my pieces and begin welding everything in place. I also made a template for my motor plate.
The magneto is mounted towards the back of the motor. I had planned on putting it to the front. When it was mocked-up I didn't like it. Everything looked more balanced with the Mag in the rear. I'm open to critiques on this portion of the build.

Sorry, I'll post the pictures in the a.m.

---------- Post added at 07:38 PM ---------- Previous post was at 07:35 PM ----------

Hey Doc, Can you imagine all the different skill sets required to build the bike in your post? Not my style at all but it has a beauty all its own. Thanks for the photo!
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Old 10-14-2014, 09:20:09 AM
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Default Re: Harley Sacreligion

Here are the pictures as promised. What are your opinions on the look of this?
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Old 10-18-2014, 02:04:30 PM
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Default Re: Harley Sacreligion

looks good to me. Thanks for sharing this project with us. I built a 500cc single and am working on a 1000 cc twin. Building an engine and bringing it to life is very addicting so have fun and keep us up to date with your project please.
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Old 10-18-2014, 07:39:31 PM
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Default Re: Harley Sacreligion

Quote:
Originally Posted by RDub View Post
Hey Doc, Can you imagine all the different skill sets required to build the bike in your post? Not my style at all but it has a beauty all its own. Thanks for the photo!
Nothing the average blacksmith, wood millwright, foundry, machinist and leather worker couldn't do.
Glad you like the pic, supposedly the FIRST official motorcycle.
Doc
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Old 10-29-2014, 06:44:57 PM
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Default Re: Harley Sacreligion

Progress is being made. I am having a shop make the tubes for the frame. I sold the other frame and am starting from scratch. The shop I'm using has a CNC Bender?! I had to laugh when he asked me how precise the tubes needed to be. My 'precise' and the machinists 'precise' are different. I made templets for my tubes with some 3/4" x 1/8" wall stock. I should have the tubes next week. This shop is also making the head stem for me. I will show the pictures when I get them back. This is not the machine shop I'm 'borrowing' to do my motor btw.
Still working on the cam chest. Made two succesful shallow bends of T6061. The third piece is giving me fits. It has the least amount of radius of the three pieces. Now, before you tell me I can't bend 6061. I know I can't! But I have The only reason I used this material is it was available and free. (scraps). I'm hoping to have some pictures soon.
Just posted so you didn't think I disappeared or flaked out. (both of which I'm adept at doing!).

rodney
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Old 02-22-2015, 08:21:04 PM
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Default Re: Harley Sacreligion

Rodney have you got your engine running yet. Spring is getting close. How about some pictures of your progress.
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