1981 Chopper Project

sly22guy · Posted: August 18, 2009, 10:39 am Post subject: 1981 Chopper Project

Im in the parts gathering stage of my chopper project. Still looking for ideas and suggestions though. Ive decided against doing a hardtail. So ive decided to do a softail.

I got a rear swingarm from a 2002 HD deuce. a 16x5.5 rear rim so i can run a 200 rear tire. im gona use the deuce rear brakes and caliper axle and suspension.

I need to locate a sprocket to bolt on the harley wheel. i know there available but just cant remember where i saw them.

As for the front im thinking bout using a hd wide glide raked triple tree and front forks. anyone running a hd frontend? Also who has the races for the neck to convert to hd bearings? Thanks for any input.

Teebs · Full Member Joined: Aug 26, 2008 Posts: 255

Hi,
I'm kind of curious as to your level of mechanical skill? How long is the swingarm pivot shaft from a deuce? It must be considerably longer than the width of the pivot mount on an xs? How are you going to make that swingarm style fit the old-style xs swingarm pivot mount? Make it look right on the xs frame?

You must plan on doing some pretty heavy chopping to the frame. I don't mean to sound condescending, but I don't really see how you're going to make that swingarm work, unless you're planning on setting up a jig and building a new frame using just the stock neck or front half of the frame and if that were the case you probably wouldn't need the level of information you're looking for right now.

You can probably get what you need for a sprocket here: www.sprocketspecialist...tMain.aspx

What is the diameter of the HD neck compared to the xs? Will they interchange?

I'm NOT trying to be a smartass. If the neck diameter is the same and the parts are interchangable from the wide glide to the XS with a race swap, I'd like to know.

sly22guy · Posted: August 18, 2009, 12:31 pm Post subject: Re: 1981 Chopper Project

Im basically gona redo the back section of the frame. from the down tube behind the motor on will be "altered". i considered widening and strectchin the factory swingarm but then i would have alot of reconfiguring to do.

Now all i have to do is makeup a new swingarm pivot joint and then and fab the mounts for the suspension. "basically all i have to do is make sure my pivot joint is true rather than make a whole frame jig for the back half." So basically i am making a bolt on rear section.

Thanks for the link on the sprocket that is what i was looking for.

As far as the neck there is a company that makes press in "cups/race" to accomodate the 1" bearings so that you can use a H-D front end on the xs650's just looking for some info from guys that have done this conversion.

Teebs · Full Member Joined: Aug 26, 2008 Posts: 255

Cool. Hope you share the build as it progresses.

sly22guy · Posted: August 18, 2009, 1:07 pm Post subject: Re: 1981 Chopper Project

i found the link for the cups for running a harley frontend on our 650's so here is the link it is about 3/4's of the way down the page
www.brosmfg.com/kits.html

PS ill def try to take as many pics as i can along the way. i figure ill keep riding it till i get enough parts or the weather gets to cold!

xsleo · Posted: August 18, 2009, 6:42 pm Post subject: Re: 1981 Chopper Project

If you get the tapered roller bearing kit for the 650. Install the races in the frame. The H-D 1 inch tapered roller bearings fit right in the races. Then use what ever front end you choose.
The stem on the Harley trees is a bit shorter, you will need to modify the top nuts for the bearings a bit to get the top tree to fit down on the stem.

LDO107 · Posted: August 18, 2009, 6:43 pm Post subject: Re: 1981 Chopper Project

sly22guy wrote:

i found the link for the cups for running a harley frontend on our 650's so here is the link it is about 3/4's of the way down the page
www.brosmfg.com/kits.html

I've seen those too but it says that you use ball bearings. How would you set up to use the tapered bearings????

QuarterHorse · Posted: August 23, 2009, 4:13 pm Post subject: Re: 1981 Chopper Project

I'll be watching this build as I'm planning on going a similar route.

sly22guy · Posted: September 19, 2009, 12:12 pm Post subject: Re: 1981 Chopper Project

Still Gathering parts what a pia. We're still gona use the Deuce Swingarm and 16x5.5 harley wheel. As far as the width of the deuce swingarm no it will not fit into the stock location of the factory swingarm. (We also want to lengthen the bike 6-8"s )

So off of the factory swingarm mount im fabing a bolt/weldin Triangulated extention. Basically it will bolt into the factory mount come back 6-8" then triangulated down to fasten to the bottom of the frame. This will house the new mount for the Deuce swingarm and also give me the mounts for the softail suspension and room to house the air tank if i go that route.

The 6-8" will also give me the extra room to do the drop seat setup. Im still riding my bike in stock form for now till i get the rest of the parts i need or it gets to cold! Very Happy

xsleo · Posted: September 20, 2009, 10:30 pm Post subject: Re: 1981 Chopper Project

You might be able to get the back half of a Duece frame from a salvage yard. Then just a bit of cutting and bending to make it fit.

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