new biodiesel harley build started

roverthetop · Post by **roverthetop** » Wed Jul 02, 2008 4:39 am

cheers, mates!
i'm starting work on my softtail bio/ svo harley tomorrow. have almost everything i need for the build. looks as though mainly harley or aftermarket harley parts will be used. only a few unhog/ fabricated bits. what i aim to do:

2002 harley softtail frame
812 cc v twin diesel
ultima 6 speed transmission

should be pretty when done i think. cant decide on the colour tho. plenty of time to figure that out i suppose. looking for 100+ mpg. real road tests will of course let us know the facts.

i'll try to post pics of the build if i remember to take them.

Adge · Post by **Adge** » Wed Jul 02, 2008 3:09 pm

All the best with that. Its a brave thing to do; the reason I bought my Harley was because I love that V Twin Harley sound. and I wouldnt reallly like to have to replace the motor with another. Would like to see the photos and be kept abreast of the build, though.

Adge · Post by **Adge** » Wed Jul 02, 2008 3:10 pm

PS Re the colour: black. Is there really any alternative?

andrewaust · Post by **andrewaust** » Wed Jul 02, 2008 3:43 pm

Looking forward to seeing the end result, should be nice with the six speed behind it. Great to see you guy's taking on some really nice builds.

Cheers

roverthetop · Post by **roverthetop** » Wed Jul 02, 2008 3:58 pm

with regards to the colour, i'm not sure i can do just black. you've all seen my bright orange dnepr and lime green kwaker... perhaps an electric pink for the harley- you see, i'm thinking if i'm to be shot for building a vegetal harley, i'd like there to be a bit more reasoning behind the untimely death!

addicted · Post by **addicted** » Wed Jul 30, 2008 10:54 am

Updates my freind updates.

roverthetop · Post by **roverthetop** » Sat Aug 09, 2008 8:27 pm

here she is. engine, inner primary and 6 spd trans. awaiting necessary motor mounts. custom turned adaptor plate in all its glory. that was an expensive piece of aluminum which is mostly lying on the shop floor now in bits. ugh.

http://img147.imageshack.us/img147/1650 ... sunld5.jpg

taken with cameraphone. apologies.

Post by **Crazymanneil** » Sat Aug 09, 2008 9:04 pm

Nice build. I am using the ultima gearbox on mine too. Will it run ok at an angle like that? I am thinking oil circulation etc, both in the crankcase and in the primary housing. If so I may run mine at an angle like that too as it would be convenient.

Still to get my motor plate made up. Hows it seal to the primary case - instant gasket? I've got a spacer for my primary to set it off from the engine for clearance. Its a standard one for bigger rear tyre harleys so has the groove on both sides. Was thinking I may machine it off on the engine side...

Neil

roverthetop · Post by **roverthetop** » Sat Aug 09, 2008 9:54 pm

the angle seems not to be an issue. i'm trying to use as many original harley parts as i can, so the inner primary is harley. a machined primary would put the trans more level, but i'm not worried. the primary will be wet unless i decide to do a belted primary. inner gasket (adaptor to punsun) is gasket material. i use cork rubber. adaptor to primary is standard harley o ring. i'm 1" belting the final as of now. rsd. seems to fit fine. motor/ trans mounts are next. about 1/8" clearance from head to trans. hope it's enough...

smokyjoe · Post by **smokyjoe** » Sun Aug 10, 2008 1:23 am

Nice job roverthetop! You're an inspiration to all. I'm still trying to get some other projects done so I can work on the bike in the garage. It is a mess, not even enough room to put the Hatz indoors!

Post by **Crazymanneil** » Sun Aug 10, 2008 11:56 am

Thanks for that roverthetop, might tilt mine too in that case. I'm using standard harley primary innner and outer to save some cash on getting stuff machined - it just about fits my application luckily. I was also able to get front sprocket with taperlock bush meaning an engine output shaft was simple and cheap compared to getting a splined shaft machined. Also means the sprocket can slide on the shaft slightly to perfect the alignment.

I didn't realise harley standard fitment is an o-ring, will have to get one of those. I am thinking I will go with some sort of gasket sheet to the engine like you have although a friend instilled some doubt as to if there is enough bolts holding it together to be oiltight against the plate I will put across the flywheel. Time will tell on this one I think.

I'm sticking with chain primary for my application although not sure what final drive will be yet (probably chain also). So she will run wet. I liked that the chain will tolerate small misalignment issues whereas the belt would run off the edge of the pully although I suppose thats an excuse for sloppy engineering.

Still to get the engine to run yet with all the electronic gubbins (Smart CDI). Does the harley alternator go inside the primary case or inside the motor? Might adapt one for my bike.

Anyhoo - hi from Northern Ireland.

Neil

andrewaust · Post by **andrewaust** » Sun Aug 10, 2008 1:14 pm

Oh boy, that primary looks like it was made for the V Twin Diesel, great job matching them up.

The 6 speed gearbox sounds the go

, nice to have a good selection of gears. Are the 6 speed boxes 1:1 in top gear or slightly overdrive. I know there was some discussion somewhere regarding Harley boxes going overdrive.

Cheers guys

Andrew

Post by **Crazymanneil** » Sun Aug 10, 2008 4:07 pm

The ultima box is pretty nice. UK stung me £80 import duty for the one I bought from the states although it was still cheaper than one here. Its reassuringly heavy and has a nice shift action from what I can tell. Only downside for me is that all the measurements are imperial wheras the rest of my bike will be metric but thats a small issue really.

The box i have is 1:1 in 5th and 0.86:1 in 6th so is overdriven i guess. The nice part about the primary chain is that I can get whatever size sprockets I want as they are 0.5 inch british standard duplex chain. (for my one anyway)

Even better you can be lazy and use the gear speed calculator here -

http://www.rbracing-rsr.com/gearspeed.html

Neil

roverthetop · Post by **roverthetop** » Sun Aug 10, 2008 4:32 pm

i am using standard 1" bore front sprocket, may go 1 or 2 teeth larger depending on what fits. on the gasket- i machined mine with very little clearance. i may use a tiny bit of liquid gasket, but i think she'll be fine. my belted final (1") seems to align perfectly. still have 1/4" on both sides for give if needed. swingarm was for a lsd, but plenty o room for my rsd. and yes, engineering takes the time. calipers and micrometers are our friends. harley alternator? or starter? rectifier? not sure what you're asking for.
5th gear is 1:1, 6th is .86. OD.
that gear/ speed calculator is snazzy! thanks for that. will employ its use when working the final for sure.

andrewaust · Post by **andrewaust** » Tue Aug 12, 2008 12:24 pm

Thanks for the info guys', the 6 speed OD Harley boxes will be a good one for the diesels, nice selection of gears, primary and secondary ratios etc.

Post by **Crazymanneil** » Tue Aug 12, 2008 9:25 pm

Yeah I think they are a good box. I thought only real option with the engine I am using (Smart CDI) that should take the grunt. Can you swap the actual gears in these bad boys? Was wondering if thats possible but not researched that route yet. Its nice that you have various options such as hydraulic clutch lifter etc and about a million belt primaries, offsets etc.

I was asking before how the harley alternator fits onto the Harley its meant for. Does it fit into the engine or into the primary case? I'd looked at harley starter motors too (up to 2kw!!) but think I will stick with the 1kw one for the engine for now as it will hopefully keep the length of engine and box to a minimum.

I never got the clutch lifter rod with my primary - do i just need a length of hardened rod to run across the box or is there more to it than that?

Cheers guys, interesting thread.

Neil

roverthetop · Post by **roverthetop** » Wed Aug 13, 2008 7:34 am

i was bored today waiting on some ordered bits for the hog build, so i started another. 1969 sportster, going cvt and veg with the punsun. nearly 1/3 done by nightfall. probably go paint shopping tomorrow. maybe metallic purple? figured this would be good for my girl. thanks again, fiddler for the aid.

roverthetop · Post by **roverthetop** » Thu Aug 21, 2008 4:24 pm

metallic purple it is for the sporty. looks good too. iridescent. seems to change colour from blue to purple and back again depending on angle and light. i like it. the pictures i take dont do it justice. maybe if the rain ever stops i can get decent photos in real light. monsoon rain in portland. ugh.
jackshaft mounted in, just need to finish up and clean up my welds. welding on my head is getting more difficult the older i get.
51t final, 20t jack.
where is the battery going to go? need to source risers. need a 2" pullback i think for the girl. pics if the rain stops....