2003 Chopper Resurrection Build

[Mr. Wright]

I loosen my lower triple tree and slid it down a little ways so you can see the problem. What you are missing is actually part of the frame. This little tab is part of the neck.


And it fits into part 44, to stop the handle bars from turning all the way, like a bicycle.does.

I think I saw an after market stop on JP cycles site that would work. I'll see if I can find it, because with out that stop tab on your neck those triple trees won't work.

 

[Mr. Wright]

Pro-One Hide-Away Internal Fork Stop Kit
J&P Cycles Part Number: 221-351

Manufacturer Part Number: 103413

This should work. If the bolts are broke off in the lower triple tree like in looks like, you can send it to me and I'll get them out for you.

 

[Tim M.]

Pro-One Hide-Away Internal Fork Stop Kit
J&P Cycles Part Number: 221-351

Manufacturer Part Number: 103413

This should work. If the bolts are broke off in the lower triple tree like in looks like, you can send it to me and I'll get them out for you.

Nice! Press-in type bearing race and stop combo. The bolts aren't broken (good) but the holes are questionable (not good) so I'm split between fill-n-drill-n-tap or different trees.


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[Mr. Wright]

Nice! Press-in type bearing race and stop combo. The bolts aren't broken (good) but the holes are questionable (not good) so I'm split between fill-n-drill-n-tap or different trees.


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You can Heli-coil them.

 

[Tim M.]

The thought had crossed my mind, I've used them in the past, not sure which kit I would need to screws that small, guess I'll need the fork stop kit to get the thread pitch. Hopefully I can make something work. A little bothered that the P.O. ground the tab off the neck to begin with. But oh well.

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[Tim M.]

So Mr. Wright, you made me curious, so I checked the surface of the frame neck lower area for indications that the tab was removed, sure enough the previous owner (not a smart dude) ground it off! I didn't catch it ( also not a smart dude lol)

 

[Tim M.]

Been a long time since I was able to post, but I'm still alive and the bike is still mine. Sitting in a full stop basically. Life has been water-boarding me with lemonade lol, now we have a damn hurricane visiting. I'm being relocated and am desperate to finish my Dog before then. Might cave and take it to a builder, we'll see!

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[Mr. Wright]

Send it to me, I'll get you done

 

[Th3InfamousI]

Been a long time since I was able to post, but I'm still alive and the bike is still mine. Sitting in a full stop basically. Life has been water-boarding me with lemonade lol, now we have a damn hurricane visiting. I'm being relocated and am desperate to finish my Dog before then. Might cave and take it to a builder, we'll see!

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Considering your circumstances and location take it to Shannon and he loves those 03/04 choppers. He will do you right!

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[Tim M.]

Send it to me, I'll get you done

You're in FL right? I have piles of new parts and mix/match, I'm up by Jacksonville. I had a guy I know who owns a custom shop in Mayport quote me $1500 to assemble the basket case, but I'm doubling that as I know it will still need the nickel and dime parts. So basically I saved for a couple years and can throw about $3k at it (give or take a few hundred). It'll be a bare-bones, no frills Chop, but I think it'll still have a chance at being pretty sharp. Hopefully.

 

[Mr. Wright]

You're in FL right? I have piles of new parts and mix/match, I'm up by Jacksonville. I had a guy I know who owns a custom shop in Mayport quote me $1500 to assemble the basket case, but I'm doubling that as I know it will still need the nickel and dime parts. So basically I saved for a couple years and can throw about $3k at it (give or take a few hundred). It'll be a bare-bones, no frills Chop, but I think it'll still have a chance at being pretty sharp. Hopefully.

I'm in Missouri, but if you really want me to do it, I'm sure we can figure something out.

 

[ewincell147]

I have same problem with my 03 bigdog chopper. Pin broke off neck.

 

[Mr. Wright]

I have same problem with my 03 bigdog chopper. Pin broke off neck.

Yeah, this is that other thread I was looking for. I knew there was another fix for that. Tim hasn't been back on here to report how it worked. Give it a try and let us know.

 

[Tim M.]

Yeah, this is that other thread I was looking for. I knew there was another fix for that. Tim hasn't been back on here to report how it worked. Give it a try and let us know.

Hola! I'm still alive and kickin'. Up for a move soon (possibly) so everything is at a grinding halt. I laid everything out to get started and was about to order the neck cup kit with internal fork stops then got side tracked by life. Still sitting peacefully in the garage, resting in pieces. I don't see any reason as to why the internal kit wouldn't suffice. Making sure the correct trees are with it helps too of course lol

 

[Tim M.]

Still kickin'. Hanging onto doing the project by a thread. Donor bike is on the lift, just trying to get The house squared away then hopefully start something resembling assembly. It's been tough, had a slew of medical issues and I've regrettably considered liquidating my 16k parts cache for $6500. Damn near 2 whole bikes and a mountain of parts. Been a long road and I'm torn between build or sell. Military life isn't helping a ton and like many I bled out a lot of money over the last 6 months. *sigh*