62 Chopped FL Rebuild
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
62 Chopped FL Rebuild
Haven't put anything up here on this bike, there's really nothing that special about it, other than I bought it in '67, and chopped it in '68, not really knowing what I was doing. It was my first Harley, after a BSA 650 Lightning, and a Honda 305 Super Hawk (my first bike, in '62). I was living on Maui in a sugar cane plantation camp, working for the sugar cane company doing surveying, drafting, and layout of irrigation systems for a 37,000 acre sugar cane farm. I pulled that '62 up the front steps and tore it down in the living room. I was a 25 yr old bachelor and could do what I wanted in that old plantation house, so it was rock n roll, beer, bourbon and buds with my buddies most days after work. I was totally uneducated about the proper way to rake the neck, had 16" over stock tubes from Forking by Frank, and wanted to run that long front end.
As I was working on it, I picked up a '59 basket case, put it together and got it running. Put the long front end on it, pulled the shocks off the rear and dropped it down as far as it would go, then made some struts to get the tire to clear the top frame cross bar, and rode it that way while I reworked the back end of the '62 frame to match it as a hardtail...
This shows the start of the rework on the '62 frame, with the '59 also shown with the long fork tubes and the struts.
And yes, I did machine some plugs to mate those tube extensions, they are not butt welded...
Just getting it set up for the first time, stock neck, radically dropped rear, axle plates cut and welded in flat (parallel) with the ground for even axle adjustment.
As I was working on the bike, I got married, my wife jumped in and helped me get the bike finished (she wanted the living room back....), I rode the bike in unfinished but rideable condition for awhile, I had a kid from a previous marriage who stayed with me a lot, he went for his first ride with me on the '62 in this pic, probable taken in 1970....
That bike got red paint, some old army backpacks converted to saddle bags, and was a daily ride, including many fun trips on the other islands with a bunch of buddies, and several trips over to the western states and Canada. Here's a fuzzy pic from one of those mainland trips...
Shortly after this pic, I converted the primary to open belt drive using one of the early Primo belt setups....
Rode it until about 1990, picked up other bikes, the '62 developed tranny and rear wheel bearing problems, so I put 'er away for a future rebuild. Along the way, I picked up a Denver's frame, I had him build one to my specs just for the '62, many years ago, and finally pulled it out of storage last year to redo the bike. Here's the start of the recent teardown of the '62....
This frame and tank went to a buddy who wants to build up his own pan, using this old frame of mine...
More later, gotta go out for Thanksgiving Dinner with a bunch of friends....
Aloha from Maui,
Willy
As I was working on it, I picked up a '59 basket case, put it together and got it running. Put the long front end on it, pulled the shocks off the rear and dropped it down as far as it would go, then made some struts to get the tire to clear the top frame cross bar, and rode it that way while I reworked the back end of the '62 frame to match it as a hardtail...
This shows the start of the rework on the '62 frame, with the '59 also shown with the long fork tubes and the struts.
And yes, I did machine some plugs to mate those tube extensions, they are not butt welded...
Just getting it set up for the first time, stock neck, radically dropped rear, axle plates cut and welded in flat (parallel) with the ground for even axle adjustment.
As I was working on the bike, I got married, my wife jumped in and helped me get the bike finished (she wanted the living room back....), I rode the bike in unfinished but rideable condition for awhile, I had a kid from a previous marriage who stayed with me a lot, he went for his first ride with me on the '62 in this pic, probable taken in 1970....
That bike got red paint, some old army backpacks converted to saddle bags, and was a daily ride, including many fun trips on the other islands with a bunch of buddies, and several trips over to the western states and Canada. Here's a fuzzy pic from one of those mainland trips...
Shortly after this pic, I converted the primary to open belt drive using one of the early Primo belt setups....
Rode it until about 1990, picked up other bikes, the '62 developed tranny and rear wheel bearing problems, so I put 'er away for a future rebuild. Along the way, I picked up a Denver's frame, I had him build one to my specs just for the '62, many years ago, and finally pulled it out of storage last year to redo the bike. Here's the start of the recent teardown of the '62....
This frame and tank went to a buddy who wants to build up his own pan, using this old frame of mine...
More later, gotta go out for Thanksgiving Dinner with a bunch of friends....
Aloha from Maui,
Willy
Last edited by 2Loose on Fri Nov 28, 2014 7:56 pm, edited 1 time in total.
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Set up the Denver's frame with an old extended springer a buddy had, just to see how it looked;
Then put the long front end off the old bike on it, with the original rear fender and sissy bar. Decided to keep it true to it's original existence as much as possible, with the Denver's frame, which I originally intended to do many, many years ago. Finally doing it....
The fork sliders were worn out, as were the lower portions of the tubes where the sliders articulated. Got new legs from Frank's (amazing that they are still in business), and put new bushings in the lower legs, and align honed them to fit the new tubes.
Fitting in more of the old parts. Gave away the old gas tank, had this new one, but had some problems moving the filler cap up to the highest location, chasing mig pinholes all over the place....
Had this tank that I like, not like the original sporty I was running, but decided to try it, see how it looks....
I like it enough that I'll keep it for now...
Got it going as a roller....
It feels damn good, now I need the motor....
Decided to try these buckhorns I cut down....
I like 'em....
Got the motor back together, nothing fancy, sixty over pistons, lotsa new small parts inside, but still essentially a slightly warmed over stock 1962 74"....
And rebuilt the tranny, then set them in the frame for a look....
Now to pull it all apart for paint and detail, then back together for wiring, lights, alla that....
More later...
Aloha,
Willy
PS, I have a whole lotta more pix on my own webpages HERE if you're interested....
Then put the long front end off the old bike on it, with the original rear fender and sissy bar. Decided to keep it true to it's original existence as much as possible, with the Denver's frame, which I originally intended to do many, many years ago. Finally doing it....
The fork sliders were worn out, as were the lower portions of the tubes where the sliders articulated. Got new legs from Frank's (amazing that they are still in business), and put new bushings in the lower legs, and align honed them to fit the new tubes.
Fitting in more of the old parts. Gave away the old gas tank, had this new one, but had some problems moving the filler cap up to the highest location, chasing mig pinholes all over the place....
Had this tank that I like, not like the original sporty I was running, but decided to try it, see how it looks....
I like it enough that I'll keep it for now...
Got it going as a roller....
It feels damn good, now I need the motor....
Decided to try these buckhorns I cut down....
I like 'em....
Got the motor back together, nothing fancy, sixty over pistons, lotsa new small parts inside, but still essentially a slightly warmed over stock 1962 74"....
And rebuilt the tranny, then set them in the frame for a look....
Now to pull it all apart for paint and detail, then back together for wiring, lights, alla that....
More later...
Aloha,
Willy
PS, I have a whole lotta more pix on my own webpages HERE if you're interested....
Last edited by 2Loose on Sat Nov 29, 2014 2:49 pm, edited 3 times in total.
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
My buddy put that old springer on my old frame, and is starting to put together another pan to look like my old one....
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
-
- NewB
- Posts: 20
- Joined: Tue Jul 08, 2014 2:37 pm
- SELF INTRODUCTION: Been building, fettling and racing motorcycle's since 1969 - now mucking about with a Japanese custom a 1987 EN450 Kwaker - plan is to re-model and style it into a bobber/chopper type thing.... I also have a 1986 Suzuki GSX750 planning to play with this one over the winter this will be an AMA superbike replice/streetfighter type thing
- Location: Portsmouth U.K
Re: 62 Chopped FL Rebuild
Cool, keep going.....
- budoka
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- SELF INTRODUCTION: I'm a Kentucky boy who's found himself transplanted into Japan. been into turning wrenches as long as i can remember. i love muscle cars, hotrod bikes, and the martial arts.
been a member of this board since back when it was a part of Chopperweb. been handling the tech side and sharing the admin duties for several years now. - Location: Fuefuki Shi, Japan
- Contact:
Re: 62 Chopped FL Rebuild
love it, love it, and LOVE IT.
-dan
-dan
-experience is a wonderful thing. It enables you to recognize a mistake when you make it again.
http://knuckleheadsummer.blogspot.com/
http://knuckleheadsummer.blogspot.com/
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Thanks guys,
I'm also looking at how I can fit a small disk brake in between those narrow front legs with that star hub, a challenge !
I'm also looking at how I can fit a small disk brake in between those narrow front legs with that star hub, a challenge !
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
-
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- Posts: 227
- Joined: Wed Aug 13, 2014 10:34 am
- SELF INTRODUCTION: I'm from Arkansas. Farm equipment mechanic. Love working on bikes with my 7yr old daughter. Single dad. Doing it all on my own. Good standing member over on the Honda rebel forum and TCU forum. My first chopper build was a Honda Rebel 250. Looking for a big brother to it. A Honda Rebel 450. I'm wanting to build a girder for the 250 and was told that this is the place to come for knowledge and help.
Re: 62 Chopped FL Rebuild
Looks great. Keep it up.
Through the Gates of Hell for a Wounded Marine.
Devil Doc
Devil Doc
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Had an '84 Suzuki front fork assembly on the junk pile, pulled it out for a look....
Also had the calipers, a pair of grease balls....
Cleaned up the left side caliper, looks good to go....
Loaded the cleaned up parts in, now to find a rebuild kit for this caliper....
Will polish up the caliper a bit more, I think it will look good on that front wheel.
Now to design a rotor carrier that will fit in and bolt to the star hub....
One inch is not a lot of room, but I think it is doable....
Aloha,
Willy
More Pix at the home server
Also had the calipers, a pair of grease balls....
Cleaned up the left side caliper, looks good to go....
Loaded the cleaned up parts in, now to find a rebuild kit for this caliper....
Will polish up the caliper a bit more, I think it will look good on that front wheel.
Now to design a rotor carrier that will fit in and bolt to the star hub....
One inch is not a lot of room, but I think it is doable....
Aloha,
Willy
More Pix at the home server
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
One question,
I'm looking at mounting the caliper either at the top of the rotor, where it would pull on the anchor link from the fork slider, or at the back of the rotor, at the 3 o'clock position, where it would be pushing up on the anchor link to the fork slider. I like the looks of the 3 o'clock position, but wonder about the effects of the caliper pushing up on that anchor link ??
Any ideas?
I'm looking at mounting the caliper either at the top of the rotor, where it would pull on the anchor link from the fork slider, or at the back of the rotor, at the 3 o'clock position, where it would be pushing up on the anchor link to the fork slider. I like the looks of the 3 o'clock position, but wonder about the effects of the caliper pushing up on that anchor link ??
Any ideas?
- Customize IT
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- SELF INTRODUCTION: I am a young punk kid that needs some help building himself a chopper!!
I am sorry I only have a hotmail account???
Tell me what I need to do I need help with my girder!!!
PLESE HELP????
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[url=http://imgur.com/fsXGYQw][img]http://i.imgur.com/fsXGYQwl.jpg[/img][/url] - Location: Ohio, USA
Re: 62 Chopped FL Rebuild
If it was a girder or fixed leg you could do that but it being but, on a springer I was told never to do that it has to pull on the bar.
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Yeah, when I try to visualize it, if it pulls on the anchor link, that can be set up so the floating caliper pulls straight and evenly on the disk, but if it has to push on that link, I can see where it might want to try to shift out of alignment and not "float" that well on that disk.
OK, 12 0'clock position....
OK, 12 0'clock position....
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
-
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- SELF INTRODUCTION: I was on the last board as bonustoolkit. I have changed that to my given name.
I started a project build there " File and Fit." I paln to continue that when I go back home in Dec. 2011. I first joined the board when Gary W had it in the year 2005. That was the time I really gained an interest in building chops. I have a long way to go, compared to some here.
Re: 62 Chopped FL Rebuild
Willy;
I really like your '58 Chevy truck. Turbo that sucker.
My '96 Buell had the disc on the riders side of the forks, at the 9 o'clock position on the right hand fork
The lower leg had 2 mounting tabs to keep it in position
I really like your '58 Chevy truck. Turbo that sucker.
My '96 Buell had the disc on the riders side of the forks, at the 9 o'clock position on the right hand fork
The lower leg had 2 mounting tabs to keep it in position
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Built that '58 truck between '95 and '98, been on the road now for 16 years, I love that truck. The 502 is absolutely bullet-proof, or more accurately, "Willy-Proof", but I keep breaking th400s, u-joints, rear axles, differentials, keep upgrading all those parts, seems pretty solid now.
A small thing on the '62, the kickstand was hanging down a bit more than I was happy with, so heated it up and bent it near where the spring attaches, got it up nice and close to the belt and clutch drum, and put a piece of rubber hose on the end where it was hitting the frame, I know that will be a rattle otherwise. Will probably put a rubber pad on the frame once all the paint, etc is done.
This is before I put that bend in it, it will lean over a little more now, but I don't think that will be a problem.
More Pix
A small thing on the '62, the kickstand was hanging down a bit more than I was happy with, so heated it up and bent it near where the spring attaches, got it up nice and close to the belt and clutch drum, and put a piece of rubber hose on the end where it was hitting the frame, I know that will be a rattle otherwise. Will probably put a rubber pad on the frame once all the paint, etc is done.
This is before I put that bend in it, it will lean over a little more now, but I don't think that will be a problem.
More Pix
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
Back to the front brake, took that Suzuki wheel apart, cleaned up the left side rotor and rotor carrier, and had to just try it on the wheel. The rotor carrier is too wide, but with it and the original front brake drum to get the bolt pattern for the star hub, I can come up with a design to fit this wheel....
Breaking down the wheel....
Parts look good....
Had to try it on the wheel, but that carrier is too wide....
More later,
Aloha,
Willy
Breaking down the wheel....
Parts look good....
Had to try it on the wheel, but that carrier is too wide....
More later,
Aloha,
Willy
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
- 2Loose
- Conventioneer
- Posts: 251
- Joined: Wed Aug 27, 2014 12:46 am
- SELF INTRODUCTION: Maui boy, farm systems mechanical engineer, sugar cane and pineapple, retired, chopped a '62 FL in '68, still have it, have five HD projects in the shop right now, three are panheads. Try to work on them every day, but often looking for or waiting for parts. Nothing stock going on here, all hot rod street oriental, and mostly old style.
- Location: Maui
Re: 62 Chopped FL Rebuild
OK, got to put these parts together....
Just stacked 'em up for a look....
one way to go....
Or mod the Suzuki carrier....
Choices, choices...
More Later
Just stacked 'em up for a look....
one way to go....
Or mod the Suzuki carrier....
Choices, choices...
More Later
The faster I go, the behinder I get....
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!
I never look over my shoulder, I know what's back there, and it scares the hell outta me !!