PROGRESS REPORTS III

Intake Manifold

Last year I put a CV carb on the bike. I really like the carb but it sticks out further than the one that I had on before. I decided to section the intake manifold and move the carb deeper in between the cylinders.

I removed about one inch from the neck of the manifold and I also tilted it slightly toward the rear. This was done purposely to provide slightly more clearance on the forward side of the carb for the linkage.

Outer Race

Rotor Adapter

Main Shaft

The custom spacer that adapts the late-model rotor to the vintage star hub. Since I am using the original lug bolts to attach the adapter to the hub I needed to get a special 3/8 - 20 tap.

Mock-up

This is a mock-up just to make sure that the spacers are the correct length and everything fits. There is a spacer behind the rotor that will be replaced with a custom adapter and there is a spacer on the axle sleeve that takes the place of the original brake shoe backing plate. The caliper is just resting on the rotor in order to make sure that there is sufficient clearance between the caliper and the spokes.

Mock-up

This shows how the smaller spacer is used to take the place of the brake shoe backing plate that would normally be attached to the fork by the axle sleeve.

Mock-up

This mockup just shows the relationship of the bracket, caliper and link.

Mock-up

It's winter here in Michigan so I dismantled the entire front end and reassembled it in my basement so I can work on it where it is nice and warm.

Spacers

In order to mock-up the disk brake I made some temporary spacers out of PVC. I wanted to use the original axle parts if possible so the smaller spacer goes on the axle sleeve and replaces the original brake shoe backing plate. The larger one is used simulating the custom adapter that I need to have machined. For now, though, I just wanted to make sure that the spacers were the right length before I actually start cutting metal.

Caliper

Yet another eBay part. This is a stock late-model (2000 and up) Harley RIGHT side caliper. The calipers on the 2000 and up FL models mounts on the aft side of the fork. I will be mounting it on the forward side of the left fork so I need a right side caliper.

Manifold Installed

Manifold installed on the bike. You can see in this picture that the manifold is tilted slightly toward the rear of the bike by design so that it will provides a little more clearance on the forward side for the linkage.

Stock Manifold

This is the "before" picture of a stock S&S manifold.

Short Manifold

This shows the manifold after I sectioned it but before it is welded.

This page last updated on June 14, 2007