Category / Projects
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Performance Sportster – Turn signals brackets
Even though it looks like a simple part, it requires 5+1 operations and a custom fixture. Quite a lot of work to just mount turn signals. Brackets are designed to similar shape as triple clamps. So that they would look like extensions and not separate parts. For this project I want high power lights all…
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Performance Sportster – Headlight bracket
Headlight bracket will allow to adapt OEM Harley-Davidson Sportster headlight and bracket to custom triple clamps.
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Performance Sportster – Handlebar risers
Designed and modeled in CAD. Height: 45mm (3/4″).Diameter: 28.6 (1-1/8″). Mounting: 1/2-13 UNC. CNC machined in house from billet EN AW-6082 aluminium.
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Performance Sportster – Fork guards
Using window machining technique because the shape itself does not allow easy workholding. This will require some hand finishing – to sand off and polish left over tabs. Forks guards are finished now. For the next time – it probably could be a little bit thinner. On the other hand, fender mounts and fork guards…
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Performance Sportster – Front fender
In most cases all the parts are 3D printed to get real life feeling. It helps a lot to understand the shape and size. I find hard to perceive shape made with white or black filament, but grey color works. These mounts are designed from two parts and not from one piece just to save…
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Performance Sportster – Front Brakes
Harley-Davidson Sportster XL1200N front hub had only one brake disc. However, the hub itself is symmetrical. So, I had to drill and tap mounting holes for second brake rotor. And now we have a twin brake disc setup.
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Performance Sportster – Front wheel
Next step for the project – mounting front wheel. Custom front wheel axle has been made from 304 stainless steel. Very simple and lightweight wheel spacers have been turned from aluminium. Inside diameter of wheel bearings is 25mm, but inside diameter of fork bottoms is 32mm. So a bushing and a nut for axle have…
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Performance Sportster – Triple clamps
The project has started – Harley-Davidson XL1200N ’08. The motorcycle has been acquired after an accident in the United States insurance auction. Imported to European Union, Lithuania. The primarily damage was to the front – bent and broken forks, wheel, fender. Many various damages all around – fuel tank, lights, handlebars. Most importantly – bent…
