The Rebirth of the Phoenix

[Gas Man]

hey gas, go easy on taping up the filter cover with the silicone on it. takes forever for that shit to cure if it is in a sealed area. i'd hate for the flames to fall off on the maiden flight of the phoenix.:2thumbs:

Good call Wood... and i'll be carefull removing that tape...

Thanks guys.

n8kam... for sure man... for sure!!!

 

[Gas Man]

So I started to TRY to finish up some things.... things that have been giving me headaches... front end with the fork brace, fender mounts, and axle; plus the headlight...

so with the headlight...
I picked up one of the wave headlights. Its a knock off of the cyclops headlight, no thanks on the real one at $750... so I guess you get what you pay for.

I wired in the stock wiring so it would just plug in to the BDM harness

It came with this dual piece mount, that I didn't want to use the one piece cause it makes it stick out and I think would make it more unstable.

so trying to mount it with the one piece, but having a heck of a time keeping it sturdy and not moving.

Tried nylon spacers and star lock washers..

didn't work GGGRRRR But still looks good I think

Tried a few different types of nylon and different washers... one of the techs at work suggested a pinch idea with a bolt and nut. Tried it and it worked. May have to upgrade the bolt to something nicer looking or cover it a bit

BUT IT WORKED!!!!!

Now onto the front end stuff. Got my fork brace back from my maching guy. Had the radious cut in on the fork brace setup

BAM! Bolts up now without spreading the forks!!!

Had the outer surface of the fork-to-strut mounts machined flat to remove material due to the forks a bit closer as desribed before.

Now with it mocked up... you can see the current spacers won't work and will need to be lathed down a bit

So mounted the front wheel to get measurements

Use the caliper to center the wheel

To be continued on this...

Lets move on...

Flipped the belt to show the other side that has not gotten the love it should... the pin striping looks great

Also, got my tank back AGAIN now without the paint saver...

then went to spin in my new gas cap adapter to find that the vent tube is stopping it from spinning in...

Say BYE BYE to that!!

Tape up for protection

Get out a small cutting wheel and the dremel... like snip snip almost... but its...going

going gone

Just to get an idea of how much I had to take off

Added some clear silicone to the threads and spun in the new adapter. the powder matches GREAT!

Here's some shots of the cap in the tank... turned out great and DAMN am I glad I did the adapter ring in black powder vs chrome

That looks great and will remain in the house for at least another day to help it cure...

Now onto MORE wiring.... YEAH!

Wired the tail lights

With these clips

LEDs

BING

BLANG

Got my replacement connectors and I will make good use of them

The task at hand

Match up the correct connector for the job

Line up the wiring correctly and slide the real seal onto the wires

slide the wires into the clip till they snap into place, then slide the real seal into place

Add some di-electric grease and a piece of shrink wrap.. clip together

Of coarse this repeated many times as needed...

Already had the lower power harness done. Now I got all of the backbone wiring done, besides the tach/speedo hooked up (still waiting on something) and I still have to wire in the aftermarket key... but its 90% done... thank God!

Also got the throttle cables and little farrels installed at the grip

This left me with this at the end of the day

 

[Chopper Dave]

Head light looks sweet! :up: and that tank looks Sick! with that powdered ring and new gas cap!:up: looking good buddy!

 

[JaiLeR]

That is smokin'! Great bike and great step through on how things are gettting done.

 

[Gas Man]

Thanks boys... its getting there... but some of this small stuff like wiring and the front end spacing... really slows it down...

 

[lee]

as I said before - one of a kind - great job Chris

 

[scubaman15]

Very good job, Chris the time spent doing all the pictures and posting outstanding!!! not many of us hear willing or able!:up: :up: :up: :up: :up:

 

[cavracer21]

chris if you need those spacers turned down, i know a guy, lol

 

[Gas Man]

chris if you need those spacers turned down, i know a guy, lol

:lol: I know... I think we thinking about the same guy... but I think that guy is going out of town. So maybe Al can do them....

 

[txchopperguy]

Man that wiring looks tedious...good man Gas

 

[narow37]

looking good man!

 

[Gas Man]

Man that wiring looks tedious...good man Gas

Dude... you have no idea... the lower harness was a bitch. I did it all and had it done sweet!!! Then I realized that I had the wiring under the rear motor mount support and NOT over like they are suppose to be. So I had to un-do all my zip ties, and completely pull the wiring to just do it ALL OVER AGAIN! Like 2 hrs wasted for a small BS thing.

Then the back bone thing was just time consuming.

 

[cavracer21]

that is true. sorry about that.

 

[Mickeetwo]

Man that wiring looks tedious...good man Gas

Chris.. the wiring is the most important thing, takes the longest time to do, but is seen the least. Good job :2thumbs:

 

[J.T.]

Whats up with the crank sensor? Does the new ignition you're using use the cam to get its reading?

 

[narow37]

Whats up with the crank sensor? Does the new ignition you're using use the cam to get its reading?

YES

 

[Gas Man]

Whats up with the crank sensor? Does the new ignition you're using use the cam to get its reading?

Yes, I'm converting to a old school style pickup can on the cam and a crane hi4 ignition in the cam cover. Not the crank sensor use and under seat ignition.

so i'm not using the crank sensor on the install so why keep it. Its ugly! But you can't find a crank sensor plug even though S&S ships the motors with it in. So I figured out that the tranny speedo sensor is the same size. I put that speedo sensor in the crank sensor hole and it fit. BAM! So I had Nelson order me a speedo sensor plug from Drag and it looks GREAT!!!!

Thanks TX... that is so true and without the wiring it wouldn't run!!

 

[TCALZ06]

That gas cap is a nice mod!

I wish someone would give us some nice options for our current paint saver

 

[Gas Man]

That gas cap is a nice mod!

I wish someone would give us some nice options for our current paint saver

Thanks man... I really like it.

 

[Gas Man]

Today just wasn't meant to be a day to get alot done. Not sure why the cards were dealt that way but they were.

I got the rear master cylinder rebuilt. Reason being, I purchased the forward controls off ebay. Don't know the "true" history on them so I rebuilt the rear master. No biggie!

Pull the rubber plunger and rod

Remove the snap ring and WATCH OUT!! It will spray, spit, and fling things at you when it comes out!!! I got DOT 5 to the eye!

What all comes out of there

Clean out the thing really well

This is how it all goes back in. The push rod would go back thru the finally rubber piece

Compress the spring and put the snap ring back in (install the snap ring SUCKS) but BAM you're done

Re-assemble the rest of the control again

With that complete I got ready to mount it to the bike. Got the baggy for the job.

Some red loctite and BAM its back on the bike

Install the brake line with new copper washers

But I did also compress everything down to one table. Tomry will be, taking more measurements on the front wheel spacers and sending them out to get lathed down to the correct size. Also, wire up the ignition, key, and coils.