View Full Version : 03 HD 1200 Custom Rebuild.

2013-07-14, 12:15 AM
Check it out. Bike belongs to a friend, and my buddy and I have been rebuilding it for him in our spare time.

Oh, and as a side note, all the powder work we did ourselves in the garage.

Ok so almost a year ago my buddy laid down his 03 xlc 1200. I was looking for a winter project so I offered to refresh his bike for him. Here is what I started with.
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130126_200758.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130126_200758.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130126_200809.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130126_200809.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130126_200858.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130126_200858.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130126_200914.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130126_200914.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130126_200926.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130126_200926.jpg.html)

Since most of the right side chrome was done we decided to go the black route. Other mods included cutting the cam cover, cutting the rear fender above the tail lamp and stop/tail/turns in the rear.

After tearing her down I started with the cam cover chop. Some info from the forum made it a simple task.

Here it is after the rough cuts with the grinder....

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130129_204547.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130129_204547.jpg.html)

More trimming and sanding...

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130203_143822.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130203_143822.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130203_143829.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130203_143829.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130203_143837.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130203_143837.jpg.html)

And starting to destroy the first pieces of chrome..

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130309_171732.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130309_171732.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130309_152303.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130309_152303.jpg.html)

I removed the entire front end and other misc items and started powder coating. Here is most of the front end after PC ready to reinstall.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130309_171747.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130309_171747.jpg.html)

After a mishap trying to reinstall the fork stem into the lower triple clamp (As I was pressing it in I forgot about the built in rake angle and blew out the back side of the lower clamp rendering it useless), I acquired an entire front end off Craigslist from an 08 XL Roadster. Which was nice since it would now upgrade me to dual disk rakes up front and matching wheels front and back

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130327_225729.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130327_225729.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130327_225737.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130327_225737.jpg.html)

Finally got most of the engine covers powdercoated and installed.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130526_221539.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130526_221539.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130526_221640.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130526_221640.jpg.html)

When we were at Sturgis, he kept looking at some of the tribute bikes around on display and mentioned he wanted to make his into a tribute bike for an aircrew our unit lost on our last deployment. Our Chinook unit is known as the Spartans and 203Cree suggested the bronze engine trim as it is a close match to the Spartan's shield color.

Figured out how to dissasemble and reassemble shocks so I powdercoated them black with a bronze spring. Stock Nightster take off's.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130601_115436.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130601_115436.jpg.html)

Next we moved to cutting the rear fender. Again couple good reads on this forum helped make this a simpler task!

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130527_150025.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130527_150025.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130527_150037.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130527_150037.jpg.html)

The call sign of the Chinook our unit lost on August 6th 2011 was Extortion 17. Staying with the tribute theme, I wanted to do something that would stand out but also be simplistic. This is the tank design I came up with.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130611_222113.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130611_222113.jpg.html)

Here is a more current pic of the bike assembled (well most of it) and on the ground. We also removed the stock Custom risers and installed a 48 handle bar clamp with some worked over 1 inch risers.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/20130612_175650.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/20130612_175650.jpg.html)

I got the rear tins Powdercoated finally. I like the Solar black flat powder.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7927.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7927.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7928.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7928.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7929.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7929.jpg.html)

I had a flat memorial bracelet laying around that I was going to use on my Streetglide but couldnt find a good place to use it on mine. One late night I decided to mount it on the lower triple clamp.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7930.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7930.jpg.html)

Here is the front end with the headlamp installed

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7931.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7931.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7932.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7932.jpg.html)

2013-07-14, 12:20 AM

After getting the fender mounted we took care of some wiring. I had to change out some pin connectors to make a stop/turn/tail module for an 04 and newer Sporty work. Got the wiring completed and went to mount turn signals and the side mount license plate and ran into some issues. I cut the studs I put on the signals too small and once the fender was mounted they didn't extend far enough to get a nut on them.

Also I bought a side mount license plate from the HD Dealer. Its for a newer sporty and figured it would fit. Turns out I was wrong. The spacing for the mounting holes didn't change so it mounted fine to the fender struts. Once I got the fender on i found out the older fenders hang down farther on the strut and was in the way of mounting the bracket.
Here is a link to the part I am talking about


Harley says it fits 04 and later Sporty's. Fitment details from the site:

Fits '04-later XL models. Will not fit models equipped with saddlebags, rigid mount sissy bars, and Turn Signal Relocation Kit P/N 68732-02A and 68733-02A

Here is some pics of the actual part

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7933.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7933.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7934.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7934.jpg.html)

It actually works out because Rob (203Cree) was changing up the rear end on his 2013 Street Bob and had no need for his stock standoffs, and more importantly, his stock side mount plate setup. It worked out great. With the plate kit mentioned above I could not run the plate vertically without modifying the kit. With the 13 Dyna mount I can run the plate vertical and not hit the turn signals. Also the 13 Dyna standoffs are about half as long as stock Sporty pieces and make the turn signals hug the fender struts a little better.

My seat from Hellpatrol came in and was able to throw it on and get some pics of the taillights and license plate bracket. Enjoy!

Turn signals with 2013 Dyna Streetbob standoffs and license plate bracket.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7959.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7959.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7960.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7960.jpg.html)

Glad we got him talked into this solo seat, I think its gonna fit nicely with the look of the bike

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7961.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7961.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7962.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7962.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7963.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7963.jpg.html)

Got to re powder coat the tank, my first attempt at a two tone powder didn't come out so well. Will try to have that done tomorrow and hopefully will have it mounted also.

When I cut the cam cover, I searched for a solution to the master cylinder mounting and found a few results that fit my situation. This is a budget build so I couldn't just order a part and had to use what I had laying around. This is what I came up with.

I took the original sprocket cover and made rough cuts with the grinder then blended out the edges. Here is a pic of the section I cut out

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7966.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7966.jpg.html)

After blending and trimming this is how it looks mounted on the bike

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7965.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7965.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7964.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7964.jpg.html)

Since I am finally happy with the part I powder coated and remounted it

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7968.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7968.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_7969.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_7969.jpg.html)

Wasn't ready to rebuild the master cylinder so I just cleaned it up and spray canned it. Waiting on it to dry for final reinstallation on the bike.

I got the master cylinder done and re mounted it. The rusty nasty looking drive pulley was bothering me so I powder coated it Bronze.

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8000.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8000.jpg.html)

Was finally ready to put the rear wheel on for hopefully the last time but wanted to get a pic of the rear lighting wiring harness I built

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8004.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8004.jpg.html)

The two tone Powder coat tank was not working (need more practice on the technique!) 203cree Had some Night Train tank badges he wasn't going to use so they got donated to the cause.

Here is the tank with just the base Solar Flat Black powder

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8001.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8001.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8003.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8003.jpg.html)

Got the emblems in place

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8006.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8006.jpg.html)

Tank is just temporaryily in place (gonna have to run throttle cables still.)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8007.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8007.jpg.html)

Also picked up a flush mount gas cap
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8002.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8002.jpg.html)

Here is a pic of the bike so far. Very happy with how its coming along. Hope my buddy is just as excited!
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8010.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8010.jpg.html)

Keep in mind, we started with an original budget of 800 bucks, or right around that. We've stayed within that budget on the whole build. Well, minus labor but when you're having fun, who counts that?

2013-07-14, 01:48 AM
In for more to come, looks good so far!

2013-07-14, 09:47 AM
That looks great... love the tank design.

2013-07-14, 09:56 AM
That looks good. I really liked your sportster.

2013-07-14, 10:01 AM
Thanks man. My Street Bob is coming along, I should have the last of my major parts in the next week or so. Haven't figured out what I'm doing for performance yet. It's a little flashier than my Sporty was, but not by much IMO.

2013-07-14, 11:16 AM
Is yours the 103 CI?

2013-07-14, 12:06 PM
No, they stopped taking orders back in May. I picked up a 96 off the floor.

2013-07-15, 08:16 AM
Awesome. Glad to see more HD builds

Gloss black pc rims would be a nice touch imo


2013-07-15, 08:33 AM
Cams, intake and exhaust should really open that 96 up. How much power do they make stock? Upper 90s?

2013-07-15, 11:33 AM
Awesome. Glad to see more HD builds

Gloss black pc rims would be a nice touch imo


Yeah, only issue is that being a budget build, he doesn't want to pop for new wheel bearings at the moment. Plus, our blaster is just a tad small for wheels, and our big oven is broke at least till the end of the week and he's anxious to ride. Can't blame him for that. May do something over the winter depending on his funds.

Cams, intake and exhaust should really open that 96 up. How much power do they make stock? Upper 90s?

Stock? 70's HP and 80's TQ. They're pretty bottled up. The right cams, a good 2-1 exhaust an intake and you can bust 100 on both.

2013-07-15, 12:29 PM
That's what I'm shooting for with the new 1250 this winter. 100hp out of a little quad cam

2013-07-16, 01:27 PM
Getting closer.....

More progress tonight! My buddy who owns it was in town and was able to lend a hand so we got to work. As He prepped the exhaust for powder and exhaust wrap I took care of some little things like throttle cables, clutch lever, ignition wires and plugs, and more boring stuff. Once he got the exhaust ready we powder coated the mufflers High temp flat black and shot the header pipes with some VHT high heat black to prevent rust after we wrapped them.

Here are the mufflers (not really mufflers since the baffles are removed and some washer lollipops are installed just to try and add a little backpressure) fresh from the oven with the high heat powder

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8016.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8016.jpg.html)

Here is the head pipes installed with the VHT paint
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8017.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8017.jpg.html)

Got the exhaust welded together so we could eliminate the clamps so the wrap wouldn't be disturbed. might be a pain in the a$$ later but hell it looks good
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8020.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8020.jpg.html)

Here they are on the bike
http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8022.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8022.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8021.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8021.jpg.html)

http://i879.photobucket.com/albums/ab356/piper1978/Sportster/Issacs%20bike/IMG_8023.jpg (http://s879.photobucket.com/user/piper1978/media/Sportster/Issacs%20bike/IMG_8023.jpg.html)

Hopefully I can get it started and timed and start working on getting the bugs worked out from sitting for a year and maybe a ride or two later this week. Now is the time I got to double check myself! Don't want to get in a hurry and forget something cause the finish line is in sight.

2013-07-16, 01:38 PM
Yeah, only issue is that being a budget build, he doesn't want to pop for new wheel bearings at the moment. Plus, our blaster is just a tad small for wheels, and our big oven is broke at least till the end of the week and he's anxious to ride. Can't blame him for that. May do something over the winter depending on his funds.

Mine is budget as well. I wanted to pc mine but ended up spending many hours in prep and painted mine with the Duplicolor Wheel Paint + clear.

http://farm8.staticflickr.com/7287/9006924538_8eec743b26_z.jpg (http://www.flickr.com/photos/mbco/9006924538/)
Untitled (http://www.flickr.com/photos/mbco/9006924538/) by MBCo (http://www.flickr.com/people/mbco/), on Flickr

2013-11-11, 06:29 PM
I remember this bike. The headlight almost killed me. Glad to see that they both will be on the road again.

Rob, my bikes being hydro dipped, I'll text you pics... ;)