JVB is a Wild Hog (light) now.

[JimVonBaden]

Adjusted the new wrap around fender for the Sportster project. It was 1" too wide, as I knew when I bought it. Took out an inch, then welded it back together. Looks great to me.

[JimVonBaden]

Someone on another forum mentioned that that seam may be prone to cracking. Knowing my welding skills I decided to see. Using a hammer and dolly I whacked it in several places to smooth out the joint, and sure enough, minor seam splitting. So I ground some spaces to reweld, then welded in some supports at the ends and middle, and tacked the inside where I wont need to grind later. I hope this solves the issues.







Held on with screwdrivers. I need to weld the holes and redrill to center and fix it in place. Looks pretty good.

[JimVonBaden]

Stripped it down for paint prep. I left the tank on for now. I need to test ride it when I get the switches in.



Speaking of paint, I sure do like this combo, especially the teal.

[JimVonBaden]

Paid $37 for a nice looking set of controls. They look really good, but the connectors were male, when I needed female. Easy you say, just swap then out. Well, not so easy. I had to figure our what wires go to what wire.

Fortunately I have the wiring diagram to go by, so I used it, and some educated guesses to get to the right color wire to color wire.






Once done, I was able to test most of the functions, and they all seemed to work. I couldn't start it, but I did turn it over. (No gas tank or exhaust.)

[JimVonBaden]

Got them installed, with the throttle. That cable assembly if friggin stupid as you need 3 hands to assemble it.





Tomorrow I will install the exhaust and tank and see if it will start! If so, I may try for a short neighborhood ride.

[JimVonBaden]

Continued work on the Sportster Turing. I added back the exhaust, gas tank and charged the battery. It lives! Not only that but the clutch works after the rebuild, and all electrics seem to work as normal. No exhaust shields as I need to no fully disassemble it for powder coat and paint, after a ride.

https://fb.watch/9U-o37nM9c/

[JimVonBaden]

Took a nice 5 mile ride to do a check run. I am happy to say the Sportster didn't leak, ran great and everything worked, especially the new clutch. The only thing is, it is LOUD. So when I got back I put on the stock exhaust I picked up for $50. It needs crossover pipe seals, but sounds much more mellow, even in the garage. The rattle are tools and parts on the lift.

FB Video: https://fb.watch/9Ys9_aOUSv/

[JimVonBaden]

I ordered the Root Beer.


I also ordered a bunch of cheap graphics that I plan to test for this: https://youtu.be/RsB9OKOW37c

Not sure what base color I am going to use. Since I have both Royal Blue and Black metallic, I am considering them.

Got sidetracked this weekend working on a WeeStrom that was a mess.




Story here: https://advrider.com/f/threads/2006-dl6 ... 836/unread

I did get the Sportster torn down for paint prep and cleaning. (see photo above.)

[JimVonBaden]

Got a start on paint prep. The easy first with thee panniers and top case, then started on the fender. Next the Vetter then the tank and rear fender.








Paint and epoxy primer is in hand.

[JimVonBaden]

Stripped the trim off the tank, wet sanded the tank, fenders (even the stock one so I have options, and Vetter. A little more touch-up to do, then prime everything tomorrow.










Love this color!

[JimVonBaden]

Now the fun part. I built fixtures for each part, then set up the "paint booth".









Wiped down with cleaner and oil remover, then tacked, then laid down some epoxy sealer/primer.








The tank has a sag, and I need to sand all of the parts. I am a little concerned with the Vetter where I sanded out some scratches as it seemed to slightly lift the under paint primer. Otherwise it looks pretty good.

[JimVonBaden]

Brought in the panniers and top case while the sealer/primer dried on the other parts.

My paint station. HF gun really works.


First coat:


Color done with 4 coats. Tomorrow I will clear with 3/4 coats.

[JimVonBaden]

Well, that was a lot of work. But the results are worth it. Added clear to the cases, and they came out great, 3 coats each.










Then moved them out of the paint booth and moved in the bodywork and fairing. Note I painted the original fender and side covers in case I wanted to use them.








Not perfect, but a great shine, and the couple of pieces of dust can be buffed out

Overall I am happy with it, and glad to be done.

[JimVonBaden]

A few next day glamor shots, some assembly started.












Overall I am quite pleased with the results. A couple small blemishes that I should be able to polish out.

[JimVonBaden]

I'm no pro, but the needed parts came out OK. My powder coating skills are sufficient.