THE PLAN

First let me say that I am not a "wrench" - never had any training in bike repair and never worked in a bike repair shop. But I am not afraid to tackle anything mechanical as long as it doesn't require any real expensive special tools or equipment. I already have a whole library of catalogs and manuals, and with on-line resources and newsgroups such as rec.motorcycle.harley available, I feel confident that I will be able to stay out of serious trouble.

So, the plan is that I will do practically everything myself. Not only to save money but because I get a lot of satisfaction out of knowing and understanding my equipment. Every successful wrench job gives you confidence to go on to the next project and also gives you some sort of a sense of security knowing that you can probably get yourself out of a jam if something goes wrong on the road.

Notice that the banner at the top of the page says that this is a rebuild and not a restoration. The term 'restoration' implies making the bike as close to factory original as possible. That also implies LOTS of $$$$$ as you search for all the NOS parts or used original parts that must be used in a restoration project.

No, what I have in mind is something that looks like a 50's motorcycle and will appear to be original to the casual observer. This will allow me to use reproduction parts and even update or modernize some things without compromising the 50's look and style.

What I don't want is something that looks like an attempt at making a chopper. So the first thing I have to do is strip it down to the bare frame so that I can have the neck de-raked (re-welding the frame is definitely beyond my capabilities). Then rebuild the front end with the proper fork tubes, some Hydra Glide tins and the correct headlight.

While I have everything out of the frame I need to do the top end on the engine - new valves, springs, guides, maybe bore the cylinders and new pistons and rings, heli-coil the valve cover screws so the covers will seal, new main shaft seal on the trans to keep the oil inside the trans.

I need to replace the rear fender and the seat. I will probably go with a reproduction fender and a spring mounted solo seat (I just don't care for the pogo seat)

I need to replace the exhaust system - I will install some staggered dual pipes even though that is not correct for this year bike.

I plan to leave the 12 volt alternator on the bike, but will completely rewire everything - probably install spots and turn signals.

And, of course, it needs a new paint job - I'm kind of leaning toward Metallic Midnight Blue, which is correct for this year.

Oh, and some bags.

So, the race is on to see if I can get everything torn apart, fixed and put back together again before it's warm enought to ride again.

This page last updated on December 18, 2006