I've had a bit of time recently to start mods on the Sporty, progress so far:

Here's some pics:

- Cut the crossover tube off the exhausts, still got to weld up the holes

- Removed indicators, I'll replace with mini's

- Removed old headlight will replace with a new large chrome one

- Removed mechanical speedo and dash, I'm going without em on this bike

- New air cleaner, I'm not sure about it though, reckon I might replace it with a polished S&S teardrop.

- Put internally wired z bars on, I love these!

- I'm in the process of mountin the tank on the backbone, and I've rellocated all the wiring under the tank.

- Rear fender and struts have been chopped, still got to do some chopping on the bottom of the fender to give it some more angles.

- Put on a Sparto tail light

Before:

Next will be:

- 11.75 shocks to go on the rear to drop the back end down, should look much better with the new fender

- Chop and lower front fender

- Paint tins satin black with flames.

- Wheels will be classic hot rod, ie red rims with white walls.

- Got the 1200 kit delivered from M&M, but will wait a couple  of months before it goes in.

Onya KC, great stuff... Looking forward to updates...

And personally I thought you were beadblasting the plastic off the cases with ya angle grinder... he he...

I remember seeing this clip a couple of years ago on how the San Francisco Hell's Angels set up their tanks.  Always thought to myself, I'd love to do it. 

Will probably go all out and do both the filler cap and the petcock mod as well.

Nice work KC.

-----Cut the crossover tube off the exhausts, still got to weld up the holes-----

If it helps, I've done the odd header crossover removal job myself in the past and found it easier and a better finish to plug a rectangular hole rather than a round one.

The rectangular plug is much easier to cut and fit using same diameter exhaust pipe as the header and the straight line welds allow for precision filing and polishing with emery cloth before re-chroming. 

I also preferred using oxy-accetylene fusion welding with a No 10 tip rather than MIG, it allowed more control with the fill and the mild steel rods produced a weld of similar hardness to the headers. But I guess that depends upon which you feel more comfortable with.

I just cut a bit of steel with a hole saw to fill the pipe & welded that in.

Ian,

Did it today, also put on 11" shocks, chrome pulley cover.

KC,

It is hard to tell from the pics but does the rear fender come past a line drawn at 45 degrees up and rearwards from the axle?

The cops here sticker anything they see that doesn't meet this rule and I am reasonably sure its an ADR.

cheers
Surly

Kingchopster build update.

I spent some time over the weekend getting the exhausts back on after welding up the balance tube holes.  I noticed at first it didn't start up as good as before needing a small bit of choke to start when cold.  But started fine when warm.  That was before the air filter and Dynojet kit was in.  But last night I put the Dynojet kit in the carb and it starts great after that.  Nice regular idle with no choke.  Power wise, before the dynojet and a/c I  didn't notice any real difference with the balance tube off but after the Dynojet and a/c a definate difference in throttle response and power.

Bike rides great with the new bars and shocks, seating position is much better.  Although being a sporty it's a bit squashed so I may go to forward ontrols.

Other bits that are done:

- New headlight is on, I didn't think it would look good until I had it on there but I like it now that's it on.

- Put in tank lift to secure the tank and wiring is neatly seated under the tank

- Cut struts and covers on both sides

- Put in engine breather

- Put front braided brake line on

Before/after:

Next up:

 - Cut and lower front fender

- Wheels are getting powdercoated

- 1200 kit install