New 800 Chopper Project

Alley Rat · 08-21-2008

My buddy phil has had his engine changing the cam chains and valve shims and is finally starting to get it back together.

This is his bike before.
We got the engine in and are going to wire it as soon. Gettin rid of the huge harness that runs under the stock tank. Only two wires will running to the headlight and everything else will either cut out or be hidden. He got the bike about two years ago and did the standard bobbed rear fender, mini apes, ditch the electrical boxes on the handle bars and what not. now we are finally getting into the fun stuff. He's putting a 2.2 peanut tank on, new rear fender and sissy bar set up, rad bars that we fabbed up, and a cool set of bird shooter exhaust. You can see the huge wire harness in this first mock up pic.

This is a mock up of what it will end up as. maybe eventually he will join me with a jockey shift. We got some mock up picks so here they are and stayed tuned for updates on this project because his bike is gonna turn out killer.

We are gonna make a reserve tank out of this A/C drier i got at the scrap yard.

El Skitzo · 08-21-2008

I wish I could ditch that wiring harness and the switch blocks from the bars, but where I am we have to have all that crap to be legal. Such as shame as it looks so much better without it all.

Thullan · 08-21-2008

Phil's before bike looks like mine, I'm excited to see where he takes it from there. Keep posting.

Alley Rat · 08-22-2008

Worked on phil's bike for about 14 hours Wednesday. His bike Tuesday night was nothing but a rear tire and frame. By the end of Wednesday we had his bike chopper wired, tank, seat, handlebars, and headlight mounted. Here are just a few pics of the wiring job.

The wiring with most of it stripped out.

Everything rewired, just needing shortened up.

Side covers drilled for his starter, horn, and headlight switches.

Taping and heat shrinking everything up.

Wiring is D U N, DONE.

Remounted front coil underneath side cover.

rogertech1 · 08-24-2008

Awesome keep posting!

El Skitzo · 08-24-2008

Moving the front coil is something I'll have to do, opens up so much space once it's gone

Alley Rat · 08-27-2008

well with the stock tank on the bike you dont really see the coil but when you change tanks you definitely have to move it.

Alley Rat · 08-27-2008

We got phil's bike all buttoned up and i don't think i have ever seen someone so happy. He has been driving his truck since May and it has been killing him not only on gas but just not being on a bike. We still got to rear fender to mount up and build a rad sissy bar along with his bird shooter exhaust.

These bikes clean up so nice with all that wiring stripped.

Seat Mounted

Good idea of how narrow this bike is gonna be. Super sixties chopper, the real thing.

El Skitzo · 08-27-2008

I really dig the risers and bars on this one!

Alley Rat · 08-28-2008

wait til you see the bars we fabbed up for this bike. as soon as he gets them back from powdercoating i'll post them. they're wicked.

A2rider · 08-28-2008

Are you going to leave the air filter hanging in the wind, or cover it a little?

jeffs99vulcan · 08-29-2008

OK, I gotta ask... is he doing all this in the living room? Os that just one hell of a comfortable looking workshop?!

Alley Rat · 08-29-2008

Quote:

Originally Posted by jeffs99vulcan

OK, I gotta ask... is he doing all this in the living room? Os that just one hell of a comfortable looking workshop?!

Yeah we were at my uncle's house and he converted half his living room into a bike shop. So anytime we are doing a long project we go over there to be in the a/c.

jeffs99vulcan · 08-29-2008

WOW!!! TOO COOL!!!

"Uh, Lysa?! Can we talk for a minute??!! You should see what the guys on the forum did!!!"

LOL

Alley Rat · 09-14-2008

Well we finally completed all the fab work on phil's bike except for the exhaust. Got him on the road running hard. We just have to paint the thing.

This is the killer sissy bar we fabbed up. Some severe work just in this thing. The beehive tail light tops this whole rear section off too.

The rad bars we built.

elr658 · 09-14-2008

You sir, get it.

jeffs99vulcan · 09-14-2008

GREAT work... THAT is chopped! Glad to see the progress!

Alley Rat · 09-14-2008

Thanks. His bike has needed a make over like this for awhile now. We are gonna put a super sixties psychodelic paint job on it too.

Thullan · 09-15-2008

Quote:

Originally Posted by Alley Rat

We are gonna put a super sixties psychodelic paint job on it too.

I'm hoping for something like this:

(from Knucklebuster)

rogertech1 · 09-15-2008

grooooveeh

08-21-2008	#1 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	New 800 Chopper Project My buddy phil has had his engine changing the cam chains and valve shims and is finally starting to get it back together. This is his bike before. We got the engine in and are going to wire it as soon. Gettin rid of the huge harness that runs under the stock tank. Only two wires will running to the headlight and everything else will either cut out or be hidden. He got the bike about two years ago and did the standard bobbed rear fender, mini apes, ditch the electrical boxes on the handle bars and what not. now we are finally getting into the fun stuff. He's putting a 2.2 peanut tank on, new rear fender and sissy bar set up, rad bars that we fabbed up, and a cool set of bird shooter exhaust. You can see the huge wire harness in this first mock up pic. This is a mock up of what it will end up as. maybe eventually he will join me with a jockey shift. We got some mock up picks so here they are and stayed tuned for updates on this project because his bike is gonna turn out killer. We are gonna make a reserve tank out of this A/C drier i got at the scrap yard. __________________ Chopper ain't dead, it just sucks right now.

08-21-2008	#3 (permalink)
Thullan Yet another 800 Bobber... BTK Expert Join Date: Dec 2006 Location: Sweden Posts: 392	Phil's before bike looks like mine, I'm excited to see where he takes it from there. Keep posting. __________________ VN800A -95 Bobber Project, work in progress

08-22-2008	#4 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	wiring Worked on phil's bike for about 14 hours Wednesday. His bike Tuesday night was nothing but a rear tire and frame. By the end of Wednesday we had his bike chopper wired, tank, seat, handlebars, and headlight mounted. Here are just a few pics of the wiring job. The wiring with most of it stripped out. Everything rewired, just needing shortened up. Side covers drilled for his starter, horn, and headlight switches. Taping and heat shrinking everything up. Wiring is D U N, DONE. Remounted front coil underneath side cover. __________________ Chopper ain't dead, it just sucks right now.

08-27-2008	#7 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	well with the stock tank on the bike you dont really see the coil but when you change tanks you definitely have to move it. __________________ Chopper ain't dead, it just sucks right now.

08-27-2008	#8 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	Ready to ride We got phil's bike all buttoned up and i don't think i have ever seen someone so happy. He has been driving his truck since May and it has been killing him not only on gas but just not being on a bike. We still got to rear fender to mount up and build a rad sissy bar along with his bird shooter exhaust. These bikes clean up so nice with all that wiring stripped. Seat Mounted Good idea of how narrow this bike is gonna be. Super sixties chopper, the real thing. __________________ Chopper ain't dead, it just sucks right now.

08-21-2008	#2 (permalink)
El Skitzo Can't find time to ride BTK Expert Join Date: Aug 2007 Location: Western Australia Posts: 683	I wish I could ditch that wiring harness and the switch blocks from the bars, but where I am we have to have all that crap to be legal. Such as shame as it looks so much better without it all.

08-24-2008	#5 (permalink)
rogertech1 Cruising In Fourth Gear BTK Intermediate Join Date: Feb 2008 Location: Yoe PA Posts: 235	Awesome keep posting!

08-24-2008	#6 (permalink)
El Skitzo Can't find time to ride BTK Expert Join Date: Aug 2007 Location: Western Australia Posts: 683	Moving the front coil is something I'll have to do, opens up so much space once it's gone

08-27-2008	#9 (permalink)
El Skitzo Can't find time to ride BTK Expert Join Date: Aug 2007 Location: Western Australia Posts: 683	I really dig the risers and bars on this one!

08-28-2008	#10 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	wait til you see the bars we fabbed up for this bike. as soon as he gets them back from powdercoating i'll post them. they're wicked. __________________ Chopper ain't dead, it just sucks right now.

08-28-2008	#11 (permalink)
A2rider Banned BTK Expert Join Date: Mar 2006 Location: KCK Posts: 19,729	Are you going to leave the air filter hanging in the wind, or cover it a little?

08-29-2008	#12 (permalink)
jeffs99vulcan Shims are our friends Forum Supporter Join Date: Jun 2008 Location: Ottawa, Ontario Canada Posts: 3,308	OK, I gotta ask... is he doing all this in the living room? Os that just one hell of a comfortable looking workshop?! __________________ What do YOU think this ticking sound is? Jeff - Ottawa, Ontario '99 Vulcan 800 Classic

08-29-2008	#14 (permalink)
jeffs99vulcan Shims are our friends Forum Supporter Join Date: Jun 2008 Location: Ottawa, Ontario Canada Posts: 3,308	WOW!!! TOO COOL!!! "Uh, Lysa?! Can we talk for a minute??!! You should see what the guys on the forum did!!!" LOL __________________ What do YOU think this ticking sound is? Jeff - Ottawa, Ontario '99 Vulcan 800 Classic

09-14-2008	#15 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	Well we finally completed all the fab work on phil's bike except for the exhaust. Got him on the road running hard. We just have to paint the thing. This is the killer sissy bar we fabbed up. Some severe work just in this thing. The beehive tail light tops this whole rear section off too. The rad bars we built. __________________ Chopper ain't dead, it just sucks right now.

09-14-2008	#16 (permalink)
elr658 Motorcycling's Dr. House BTK Expert Join Date: Nov 2004 Location: Seymour,CT Posts: 3,606	You sir, get it. __________________ 1982 Kawasaki KZ1000R1 #658 1980 Kawasaki KZ750H1 LTD www.myspace.com/79cb750f

09-14-2008	#17 (permalink)
jeffs99vulcan Shims are our friends Forum Supporter Join Date: Jun 2008 Location: Ottawa, Ontario Canada Posts: 3,308	GREAT work... THAT is chopped! Glad to see the progress! __________________ What do YOU think this ticking sound is? Jeff - Ottawa, Ontario '99 Vulcan 800 Classic

09-14-2008	#18 (permalink)
Alley Rat Turtle Wax Taster BTK Intermediate Join Date: Mar 2007 Location: ruston, la Posts: 155	Thanks. His bike has needed a make over like this for awhile now. We are gonna put a super sixties psychodelic paint job on it too. __________________ Chopper ain't dead, it just sucks right now.

09-15-2008	#20 (permalink)
rogertech1 Cruising In Fourth Gear BTK Intermediate Join Date: Feb 2008 Location: Yoe PA Posts: 235	grooooveeh

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