1978 Harley-Davidson Sportster

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Steven M - click this image to see my build

What was your intended objective when you started the build?

Use as many Harley-Davidson parts as I could
Even if I had to modify them. Also, everything had to be done by myself. The ONLY think I farmed out was getting the cylinders bored out. I even bored out the cases with a modified drill press that I also used as a mill. PITA!

What motivated you to start your project?

I wanted to teach myself to TIG weld aluminum.

S&S

What was the most unique and creative thing you did to the bike?

Welded up the cases and fit a 74” Shovelhead Top End on it and squeezed it into a relatively stock 78 Sporty frame.

What are you most proud of?

Learning how to TIG weld. One of the most difficult things I have ever tried to learn. The worst part is that the learning process never ends either. All those bottles and bottles of Argon gas! My god! I spent two years screwing around welding up those cases and burning my arms, legs, etc with molten aluminum that would “ball up and roll” off the cases and always on me and never the floor! I refused to pay someone else to weld them. I’ve always done my own work and wasn’t going to “throw in the towel”.

What do other people say about your motorcycle?

🤷‍♂️ My sister said you needed sunglasses when looking at the paint!

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Submitted by: Steven M

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Specifics

Make, Model & Year: 1978 Harley-Davidson Sportster
Time spent: 4 years off and on. Didn’t keep track of hours since I’m retired and time was of no concern. I probably averaged 4 hours a day. Most of that time was spent learning to TIG weld aluminum. I’ve got the burns to prove it! Molten aluminum is HOT, HOT, HOT and painful when it balls up and rolls onto your shoes!!!!
Motorcycle cost: $300
Money spent: $10,000? Hell, I didn’t really keep track. Money Wasn’t the point.
Engine: Harley-Davidson 1978 lower end modified for Shovelhead +.060 over (74”) top end. Andrews Y grind cams, Sifton Tappets. Trock trap door. 4-5/8” Stroker with S&S flywheel, S&S Heavy Duty rods, and S&S Stroker Pistons. The battery is a 330 cca AGM glass mat coupled with 4 gauge battery cables to a 1.6 Kw starter. I also used 2 standard braided ground straps. Had allot of trouble getting the engine to turn over initially because of the extremely high compression. That’s a story for another time but I literally blew the front jug right off the cases. The jug just disintegrated into a thousand pieces and cracked vertically as well as searing in half horizontally …. 🤷‍♂️🤷‍♂️🤷‍♂️ Seriously!
Intake: Carbureted S&S Super G with 1-1/2 manifold extension and internally screened velocity stack
Exhaust: Modified stock Shovelhead front pipe and modified Shovelhead Drag pipe in the rear. Heat shields modified from 2016 Dyna. Front muffler is from a 1982 Sportster and the rear is from a Dyna (I think).
Transmission: 4 speed Andrews gears and Trock trap door. I also added heavy duty Trock clutch spring and Barnett plates. That required 4 gorillas and a clown (me) to pull in so I added a hydraulic clutch from “Machinist Mike. Inc”. Now it just takes a clown to pull it in.
Frame: Stock Harley-Davidson Sportster with modified backbone to clear rear head and fit the Dyna-Tek dual coils. Front fender stock Sportster from a 2003 and the rear has been “bobbed” from a 2006 Sportster. Oil tank and battery tray had to be modified to accommodate the rear head and exhaust pipe.
Suspension: Rear is a Modified 1981 Harley-Davidson Sportster swingarm. Strengthened internally, for shock relocation and fitting for a stock 2003 Sportster caliper assembly. Front is stock 1981 Harley-Davidson lowered 1-1/2 inches or so and has +3 degree raked cups with tapered Tiken bearings.
Wheels, tires and brakes: Front tire is an Avon Speedmaster MK II 3.25 x 19″. Rear is a 140/90 Continental SuperTwin. Rear disc brake is from a stock 2003 Sportster. Front dual discs from an 81 Sportster.
Finish – Paint: All paint done by myself. Color is 1970 Chevrolet Hugger Orange straight lacquer with DuPont 496-00 clear Urethane top coat.
Accessories: Well hell, I needed a power outlet to charge my phone and light my cigarettes. Also needed an area to store some tools. It’s still an Ironhead and I don’t ride without some basic tools.

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