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Old 02-22-2018, 10:11 PM   #1
FXDS1340
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1997 XLH1200

Sporty I'm building. Just another place to keep track, and post pics. Not going to post all the details quite yet as they're being ironed out. Either way, it'll be laying down 100+ to the rear wheel in another month or two and might have the rev limiter set at 8 grand.
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Old 02-26-2018, 07:21 PM   #2
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Bottom end out, and cases split. Going to have the right case half anti-rotation pins drilled and tapped and converted to the screw in style found on 2000 and later sportsters. Necessary on high performance applications. Going to have the pinion bearing and race checked out as well. Looks fine, spins fine, feels fine, but I don't have the tools or equipment to do big end work. Only thing from here on out is re-assembly.
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Old 02-27-2018, 12:33 PM   #3
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nice!!
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Old 02-28-2018, 09:34 PM   #4
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nice!!
Thank you. Building these old bikes is a lot of fun.
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Old 03-01-2018, 10:05 AM   #5
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Love it! Can't wait to see more of your progress!
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Old 03-01-2018, 09:33 PM   #6
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Dropped the bottom end off at my machinist yesterday. Going to punch the crank out the left case half to make sure it's within spec. When you're planning on really zinging these single pin cranks, you gotta make sure they're good to go. Going to get the right case half tappet pins drilled and tapped for 2000 and later tappet anti-rotation pins. These screw in rather than slide in, and are much stronger. Also going to have my S&S E milled for a thunder jet. Problem with S&S carb's is they only have 2 circuits, and those 2 circuits work well at idle and off idle, and WFO... leaves a lot to be desired in the middle. Adding a thunder jet really helps on a performance build.

Oh yeah... engine parts are on the way! Still a long way to go though.
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Old 03-05-2018, 09:00 PM   #7
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Fire in the hole.
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Old 03-06-2018, 02:01 PM   #8
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WOW!! That's major maintenance! Was something wrong with the bike when you got it? Those Sportsters engines are very reliable.
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Old 03-06-2018, 08:36 PM   #9
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WOW!! That's major maintenance! Was something wrong with the bike when you got it? Those Sportsters engines are very reliable.
Nothing wrong at all. Ran really well actually. I'm 100% a Harley guy thru and thru, but not the type of Harley guy you typically see. I don't run around in little skid lids with vests on that have cliche patches and all that dumb stuff; I wear full gear. Even though I work at the top dealership in Texas and love all the new bikes, there is not one I would own. Don't get me wrong though. I have ridden all the new Softails and there is no competition in the cruiser market. Best cruisers you can buy. I'm more into the old school build your own scene. Was born and raised around it. Every H-D I've had except that twin cam heritage I had for 6 months I built myself, and they were all fast. I won't own anything made after 1998 except sportsters as long as they are rigid mount.


Heads came in today. These should get me over the 105hp mark without a lot of work. They're a good base for when I shoot for a 150hp 90" build in a few years.
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Old 03-07-2018, 11:49 AM   #10
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Great project and thanks for sharing.

I like the new Softail frame withe the M8 engine. Too bad the 2018's are too expensive and out of my reach. I really like the new 2018 Fatbob.

No idea if the M8 is all that great as they say. IMHO the most advanced engine created by HD was the V-ROD engine and they just kill it last year.*

I have own a total of six Harley's and so far only one issue with the 2011 Fatboy, the check valve start leaking fuel. I tried to fix it on my own but was not able to pull the o-rings out. Good thing I got the extended warranty.

If I recall correctly I have own them in this order:

1) 2007 VRSCD Nightrod
2) 2011 Sportster Iron 883
3) 2008 Softail Rocker
4) 2007 VRSCX V-ROD
5) 2006 VRSCR Streetrod
6) 2011 Softail Fatboy
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Old 03-07-2018, 09:04 PM   #11
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The new Milwaukee 8 is probably the best engine they have had to date. They took all the positives of the evo and the twin cam, none of the negatives, and meshed it into one engine. You have to remember that all twin cams have a pressed together crank... they were fine from 1999-2002 when they still had dual tapered timkens on the left half of the pin and pressed into the left half of the case. Starting in 03 they lost their contract with timken and had to go to a straight roller bearing. They also went to sealed wheel bearings, and some other neck bearing. Low and behold you started having bikes with crank run out issues, wheel bearings going out in 20,000 miles or less, and bikes eating neck bearings often. The neck bearings, and wheel bearings in my 1996 FXDS were original to that bike even at 100,000+ miles. The crank? It had 11:1 static compression pushing down on it... I beat the ever living out of that engine. It ran like a top until I managed to really hurt it.

With that being said, the new Milwaukee 8 has a really unique component of it. The counter balances are gear driven off of the crank. Because of this, crank runouts like Panhead, Shovelhead, Evo, and pre 2003 sportsters have to be less than .002, preferably .001 or less. With a chain (aha, chain driven counter balancers in softails and chain driven cams) you can have crazy high run outs because a chain can flex and bend. Gears cannot. I have seen some high mileage Milwaukee 8's already and have had the pleasure of riding them. Unlike their poorly made twin cam counter parts, even at higher mileage they are still as quiet as can be and FEEL tight. No rattling or shaking around. They remind me of a well built evo.
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Old 03-12-2018, 08:56 PM   #12
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All engine components are in. Still haven't gotten the big end back yet. When I do I'll paint everything, and go back up with re-assembly. I have a friend of mine who hand makes things out of brass and last year made me some acorn nuts, screws and stuff for my Heritage I had. I never got around to putting them on that bike. I'm going to see how I can incorporate them into my sportster build.
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Old 03-18-2018, 08:44 PM   #13
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Well, everything except the big end is ready to rock. Stock cam compared to the Impact 560. I'm already wishing I had found some Buell heads instead and had them worked over, ran some 30* reverse dome pistons, and a .600 lift or higher cam with more compression, but I got what I got and I'm going to run it.
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Old 03-20-2018, 07:30 PM   #14
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Swapped my drive gears after work in the shop. One step at a time. This is cheapest way to make sure you donít have gear lash issues. You can purchase a new pinion to match the drive gear on your new cam, but if you donít have mics and gauge pins it becomes costly. I have all that but at least this way I know itís done right, and itís super easy. 20 ton press does the job well.
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Old 05-10-2018, 05:49 AM   #15
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any updates on this? great read so far!
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Old 05-10-2018, 09:49 PM   #16
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any updates on this? great read so far!
None really. Still waiting on the bottom end, but I did pick up some nice 9 spoke mags that I'm going to either paint or re-powdercoat. Now that summer is here this project will move a little slower. I can only tolerate sweating my off in the garage so much. I also picked up a 14 FLHX that has cams and head work that is keeping me occupied with laying black strips on the pavement.
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Old 05-15-2018, 10:15 PM   #17
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Rode the glide with my wife on Sunday. A 900lb should not move as good as this one does. Lights the tire two up. Got some legends Revo-A's on the way for the end to make it ride a little nicer; I'll do something with the front end later.
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Old 05-16-2018, 08:12 AM   #18
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That Sporty is gonna run! I bet you and Skelator (MH Guy) would get along real well. Cant wait to hear video of it run.
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Old 05-16-2018, 09:13 AM   #19
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Sweet build! I'm curious about the Timken main bearings. You mentioned those stopped in '03, did they get added back as one of the updates in the '08 and later XL / Buell engines? I'm curious as I have an '07 XB I'd like to hot rod a bit. Is it possible to 'upgrade' the later cases, or is it even worth it to do so?
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Old 05-18-2018, 09:46 PM   #20
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Sweet build! I'm curious about the Timken main bearings. You mentioned those stopped in '03, did they get added back as one of the updates in the '08 and later XL / Buell engines? I'm curious as I have an '07 XB I'd like to hot rod a bit. Is it possible to 'upgrade' the later cases, or is it even worth it to do so?
To be honest with you I'm not entirely sure, but I do know this. A popular conversion for hot rod Evo XL's like what I'm doing is to do a buell XB crank. I don't know if they necessarily use a dual tapered Timken set up, but the crank pin is fawking HUGE and the rods are on par, if not better than carrillo rods. Requires a little machine work of course. Definitely a lot better than the stock crank. I'm really running a risk by putting this much compression and power on top of a stock crank, but I'm hoping by knife edging, re-balancing, and rebuilding with carrillo rods etc... I can avoid some of the issues, especially if I set the rev limiter at 7300. Without getting lost in technical jargon, I guess what I'm trying to say is that you already have the best crank money can buy. The bottom end on your XB should be able to handle whatever you want to do and then some.

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