Patent Pending

FOR ROAD KINGS & SOFTAILS!

Klock Werks designed the FLARE windshields from a need for downforce on their Bonneville Land Speed Bike, the WFB. Be sure to look for the ORIGINAL, wind tunnel tested, patented FLARE'" - now providing downforce in more sizes than ever before!

KUSTOMBAmRS.COM

klock werks windshield limited

o we wanted to throw out a cool ^ tech article for the home shop mechanic this month since this is where so much of the scene is coming from today. We l^r decided that there would be no better place to go for a "how to" on hardtailing a Sporty than to the cats at Led Sled Customs. Pat and his crew will be installing one of their two inch hardtail kits for us here. More importantly, they will be doing this to show that you can do it at home without the benefit of a fancy frame jig. By following along as they chop a '95 Sportster for a customer, you can learn the tricks of the trade from them. The Led Sled Sporty kit comes complete with an oil tank and battery tray that have been pre-mounted. Additionally it comes with a rear fender, complete mounting brackets, an axle and pre-welded adjusters. The tools you will need to get this job done are a sawzall, hammer and wood block, Tig welder, grinder and deburring tool. Well, of course it would also help to have all the basics and a shop manual to help you rip the thing down and put it back together. So let's take a look.

Here we are getting ready to start the job. The stock frame has our mock-up motor still in it and we will use it as our frame jig.
You don't have to take your frame down this far but the important thing is to leave the top and front bottom motor mounts on.

you rip the thing down and put it back together. So let's take a look.

Rather than trying to give exact measurements, we use this method to custom fit the hardtail to each frame.
Here we set the new hardtail directly beside the stock frame and eye-up a rough idea for placement.

Starting with the bottom rails, we now begin to cut away the rear of the stock frame. If you are leaving your motor in for this step, you may want to cover anything that could be damaged or is open.

By comparing the distance between the motor mounts on the frame and on the engine, you can determine the exact location of your next cut. We're pretty close so we re gonna move on to the next step.

The plug weld holes are 5/16 holes that you drill into the stock frame that will be filled with weld later. We can now clean the surface of the slugs on the hardtail section and prep them for welding as well.

At this point, we make some lines on the frame with plenty of extra room to cut to a closer dimension the second time just to get the rear of the frame out of the way.

Starting with the bottom rails, we now begin to cut away the rear of the stock frame. If you are leaving your motor in for this step, you may want to cover anything that could be damaged or is open.

With the rear of the stock frame detached, we can now slide the hardtail into place and begin to take closer measurements for a more precise cut.

By comparing the distance between the motor mounts on the frame and on the engine, you can determine the exact location of your next cut. We're pretty close so we re gonna move on to the next step.

With the frame cut to the proper length, we can debur the inside of the frame rails to accept the slugs of the hardtail and drill plug weld holes.

The plug weld holes are 5/16 holes that you drill into the stock frame that will be filled with weld later. We can now clean the surface of the slugs on the hardtail section and prep them for welding as well.

Was this article helpful?

0 0

Post a comment