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Discussion Starter · #1 ·
I built a GL1100 as my last project, which I've been using as my main transportation since I got it on the road.

I wanted something to work on and my GL is my only transportation right now so it can't be ripped apart. The only answer was to get a second bike. My mom had this 06 Sportster Low that she didn't ride any more. She was trying to sell it for a while with no takers, then one day her husband was moving it to storage for her and he rode it into the side of a car on the highway. He escaped with some stitches and rash. I guess he fixated on a curve in Arkansas. Fast forward, she can't sell the bike, he was unlicensed and uninsured, so the bike isn't getting fixed by insurance and he isn't mechanically inclined. On top of that, the accident spooked them both so they decided no more bikes. So she asked if I wanted it, and I said hell yes. So I went and picked it up. With gas I got it home for under a thousand into it. I forgot to get pictures as I picked it up. It was a pretty standard 1200L with a solo seat, saddle bags, crash bars, and pink flames. Yeah. The bars were folded into the tank, the front fender is dinged a bit, speedo broke, the crash bars were tweaked and ground up, the left controls were ground up, the lights broken, and the saddle bag ground down. Mostly cosmetics, some minor mechanical things, but it runs and everything important seems straight. First thing I did was start stripping it down to assess it all. The foot peg brackets are CRAZY heavy. They're like solid chunks of cast iron. I bought a normal 3.3 gallon sportster tank for it (I like the look, stock is the uglier 4.5 gallon). I can deal with the range, my GL has 5.5 gallons. I also got rid of the bars and bought clubmans.



I did some minor generic sportster stuff. Bought some metal from Ace Hardware and moved the ignition to the side of the engine, made brackets to lift the tank and tuck the wires. I was looking at sportster forums and all the dentists were doing the same "mod" to tuck their wires and they were PRAISING the prices for the "kits" that cost $80-$100. I couldn't believe it. It cost me under $10 for the metal and hardware, all in stainless. I actually lifted the tank more in the rear because I wanted it more level rather than angled back.

Then I picked up some Basic HD pegs and threw some rearsets on it. They're reverse shift, because it's cheaper and simpler and I didn't want to deal with linkage. Er no, I mean because it saves weight... Then I got some poster board and made up a simple tail section. This just to help visualize and figure out what I want to do.

I also picked up some shocks. They're branded "Burly Brand" who I had never heard of, but as far as I can determine they're actually made by progressive. I went from the stock ~11.75 Low shocks to ~15" to really raise the ass and sharpen the front end up a bit. Here is as it sits with the seat template.

I've got to find my grinder and get rid of the rear frame rails/struts. The belt rubs the stock rear master cylinder mount, but I'm going to pull that off since the master cylinder is on the rear sets now. Plus it's another cast iron looking piece. I think HD looked at the parts that the Japs usually make out of aluminum, and said "Aw hell naw, this is 'Merika! We use REAL iron, none o that flimsy 'lum'num shit! I can get AT LEAST another 60 pounds on here!"
I'm also hunting for a welder. Planning on making a custom under tail exhaust and moving the oil tank I think. Once I get it all nice and ridable, I'm planning on building the engine. Haven't decided what route to go. 1250 or 88/90". Probably just the 1250 with worked heads and so on. Still kind of figuring it all out.
 

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Discussion Starter · #4 ·
You know, I always said I would never buy a Harley, but this one was basically given to me. Plus I rode a friend's hot rodded Sportster last year and it was a TON of fun, even with the stupid forward controls and drag bars.
 

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Custom bikeporn addict.
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Careful with how much you raise the rear. It's hard to tell exactly from the picture but it looks close to having zero or a negative trail. Could be tankslapper city.

Loving the look though. Is there room to drop the front of the tank a bit to bring the bottom of the tank more inline with the frame rails? Could save you some work having to chop it.

Bob
 

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that tank really needs to come down quite a bit!
Raise the tunnel and you'll get the clearance needed for the relocated wiring AND it will be able to sit lower.

I'd take an old xlch sporty any day over a brand-new twincam or something.
 

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Discussion Starter · #7 ·
Good call. Trail is good, the picture makes it look bad. As for tank height, the main reason I lifted it was to get the angle I wanted, the wiring was just a bonus. I'm still tinkering with it. Once I settle on an angle and height in going to weld the tabs instead of using metal spacers.

I didn't get much done today. Bought some harbor freight tools. Took the tank off and started figuring out what to cut or grind off.
 

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Discussion Starter · #8 ·
I had today off so I broke out the sawzall and grinder and chopped off some unnecessary bits, then sprayed them with black rustoleum enamel. Not a pro finish but should work for now. I also broke out the dremel and made some more room in the tunnel so I could drop the front of the tank down a bit more. Also got the stock rear MC mount off. That thing weighs like 5 pounds. I swear everything that would be aluminum on my Honda is lead or cast iron on this thing. Here is how it sits.



I'm going to start looking for a welder I can afford so I can modify the rear tank mount instead of using bolt on extensions. Then I'll be able to make my exhaust, too. I should have my aluminum sheet this week so I can start trying to make the tail.
 

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Hack in a barn
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I'll be honest, at this point I have no idea where you are going with it, but I can't wait to watch you see it through to the end and achieve what is brewing in you head :D
I mean that in the best way possible lol...
 

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Discussion Starter · #11 ·
lol, I hear ya. to each his own. I know I watch threads and sometimes I can't figure out what the builder sees in his head. sometimes it all comes together in the end, sometimes it doesn't. Hopefully this one does.
 

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Discussion Starter · #12 ·
Made a rough tail out of aluminum and threw it on to see what it looks like. and got rid of the front fender. Small updates but if I don't keep on it I'll forget.

 

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Discussion Starter · #14 ·
I took a very long break from this as I got a Jeep Comanche I was tinkering with, plus I do all my work outside in my apartment parking lot, and winters suck here. The site seems kind of dead compared to the old days. Kind of lost my motivation and direction for a while. Now I'm changing the plan a bit so I've got to figure out some things. Here's as she sits.




Still tweaking on it of course, and still have some fab work to do. borrowing a welder in the next couple weeks. And I'm still deciding what direction I want to go. It always sucks changing your mind after buying parts.
 

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Isn't as dumb as he seems
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I took a very long break from this as I got a Jeep Comanche I was tinkering with
Oooooooh, tell me more?
I think I'd sell my soul for a clean 4x4 Comanche with the 4.0.
 

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Discussion Starter · #18 ·



Had a death in the family, emergency road trip across the country, no time or energy. Finally made some progress and this is as it sits. I have to adjust the seat position and stuff. and I think I'm going to get some tracker style bars. But I've been riding it and enjoying it. The rear brake master seems to have died on me. Apparently that's common on these. Still lots to do, but I'm happy to be riding it.
 
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