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Project: Drain Plug for 2004 Bulldog

Discussion in 'How-To' started by chacha, Dec 9, 2007.

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  1. chacha

    chacha Chaff Your EHC!!
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    OK, some of the models in later years have a decent drain plug built into the frame. My 2004 has this two-bit drainline with a plug stuffed in the end and it's tiewrapped to the frame -- works, but a pretty crappy set-up. Even the 2001 HD has a drain plug built into the frame.

    Besides, last summer, one of the techs screwed up and failed to tiewrap the line. The line tapped against the belt and the bike got a nice oil bath at 60 MPH -- not fun.

    So after a few beers and a trip to the hardware store, I figured a way to mount up my own drain plug that would be fixed to the frame. It also gave me the reason to change out the last oil line over to braided steel.

    What it takes is a flat gate reinforcer (~3 inches), and 1/8 NPT gas line (~ 4 inches) and a cap. Here's the basic idea;

    [​IMG]

    Bending the reinforcer around the gas line gives a good surface to weld against (green arrows);

    [​IMG]

    I didn't want to count on the welds when I changed the oil, so I tapped out the thread longer and tapped out a nut to act as a locknut;

    [​IMG]

    The locknut is on with red locktite. It will be held to rotate off the drain plug.

    [​IMG]

    It sits close to the rear shock bolt so it will have to come off when working on the shocks. So far it's been on for four months, no problems.

    What it looks like mounted up;

    [​IMG]
    [​IMG]
     
    Tim likes this.
  2. hoat

    hoat Well-Known Member

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    sweet nice job chacha! cleaned that right up!!!
     
  3. P8RIOT

    P8RIOT Well-Known Member
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    Yeah, nice job, Chacha - very professional looking fix. :up:
     
  4. Tim

    Tim a.k.a. BubbleHead
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    Very cool! :2thumbs:
     
  5. Gas Man

    Gas Man Cool isn't cheap
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    Good mod for the older dogs...
     
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