82 Bagger

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txtriathlete
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Re: 82 Bagger

Post #16 by txtriathlete » Sun Oct 27, 2019 5:46 pm

Made some progress on getting the shock stuff sorted. If I can figure out the oil, spring and air combo to permit fully compressing the OEM air shock (and still being able to ride in full inflated mode) I think I can get it where I want it. The OEM will compress to about 9.5" (without any internals). It looks like the rubber dust cover will also compress enough not to cause interference, there's about an inch and a half of shock below the can and the cover compresses down to about an inch so it should be ok.

Some pics:
Image

About 9" of ground clearance when fully compressed.
Image

Looking at it in mockup I think the center stand may have to go away. Which then leaves a nonsense "dent" in the exhaust where the center stand leg tucks in. Not sure which annoys me more at this point.

That said, once its on the ground and I have the extended front forks put on, it may drag the exhaust tips. But since I'm only planning to slam it for static display and not riding, it should be ok. Fishtails would be da bomb...
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

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Track T 2411
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Re: Modifying GL1100 Air Shocks

Post #17 by Track T 2411 » Sun Oct 27, 2019 7:22 pm

20190711_151144.jpg

This is what I use to replace the bumper. Available on Amazon, eBay, etc... The center hole requires enlargement, but it's pretty easy.
You do not have the required permissions to view the files attached to this post.
"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.

txtriathlete
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Location: Rapid City, SD

A shocking solution

Post #18 by txtriathlete » Tue Nov 05, 2019 6:56 pm

So I looked into purchasing aftermarket air shocks, but they are more than I want to pay if I don't absolutely have to. I thought for a bit about how I might be able to use the stock shocks in an "air only" mode in order to get full compression since the springs prevent the shock towers from collapsing completely. After puzzling a bit on what I might do to modify the factory shocks, I think I have hit on an inexpensive solution. Turns out its actually not that hard.

After pulling the shocks apart
Image
I reassembled the shocks minus the springs and spring pieces - this stuff:
Image
That worked OK until I ramped the pressure up to 100 PSI, when this happened:
Image
This happened because the top of the shock and the upper tube are press fit and not screwed together. Normally the springs hold the shock top tight to the upper canister to keep them from separating. Without the springs, I had to find a way to hold the top of the shock secure to the upper canister.

After thinking on it a bit, here's what I came up with:
Image
I welded a 1/2" fender washer to a nut and threaded it onto the shock. I was then able to thread the shock top onto the shock (washer inside the upper canister) until it was snug against the washer. The washer is wide enough to contact the top of the upper canister so the top is now secure and won't come loose. After test fitting, I pulled it back apart and made a couple of cuts in the washers with a cut off wheel to open up a passage for air to flow into the shock (the small hole on the shock top is where the air comes in). The cuts also make a handy spot to slide a large flat tip screwdriver blade into in order to move the washer around or to hold the nut/washer still when I need to unscrew the shock top next time.

Then I put it all back together
Image
and stuck it on the bike.
Image

But would it hold air?
Image
So far the answer is yes.

I've had it up to 160 PSI for a few hours now with no air loss so I think I am good. Obviously I can't ride the bike to test it further, but I have bounced the bike hard quite a bit and it seems solid. I won't know for sure until I ride it though which is still a long time away.

At 160 PSI there is about 5 1/2" clearance between the rear rail and the tire - full extension.
Image

When I let the air out (70-80 PSI seems to be the deflection point) I have about 1 3/4" clearance.
Image
This is probably low enough for my purposes, I don't think I want the frame (or eventual fender) to actually make contact with the wheel in case the shock decides to let its air out on the road somewhere.

Also, while there are no springs in the shock, there IS oil. ATF to be exact. This is one of the nastiest (30 year old shock oil, anyone?), messiest jobs I've done lately. Having to blow out the seal with compressed air while the shock is full of oil is a nightmare.

Anyway, at this point that wraps up what I wanted to get done on the back of the bike for now. I'll figure out where to locate the air compressor and so on when I actually get to the build part of the project.

On to the front...
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

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Track T 2411
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Re: 82 Bagger

Post #19 by Track T 2411 » Tue Nov 05, 2019 7:43 pm

Nice out - of - the - box thinking. It will be interesting to learn how it rides. One issue you might consider is the type/ size of compressor you'll need if you have to run 50+ PSI. Most portable compressors can't provide that much pressure.
I would also suggest not using the original air lines at those levels. They are nearly 40 years old, after all. I've thought about having new lines made for my 1100, but haven't checked into it much. I did happen to see similar fittings, etc. at a hydraulic hose shop (Parker) while getting some hoses made for work...
"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.

txtriathlete
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Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Re: 82 Bagger

Post #20 by txtriathlete » Tue Nov 05, 2019 7:59 pm

Yes, compressor and lines will be new. Stainless, like brake lines if I can find them. I was actually surprised these held for the testing. I was waiting for one to pop partway through. I've looked around online at pumps but not seriously yet, Amazon has 150 PSI pumps for $50 but who knows if they are any good.
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

txtriathlete
Cast Iron Member
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Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Front End Service Question

Post #21 by txtriathlete » Thu Nov 07, 2019 10:25 pm

Got most of the front end torn down today, but am now stuck on getting the head bearings out. Specifically the nut at the top of the triple tree. IIRC, when I did a GL1000 a while back, I used a hammer and screwdriver and hit it until it started to turn. I tried that with this one but its not turning and the slots in the nut were starting to deform a bit. I assume this nut requires a special unobtainium Honda tool, has anyone made one - like for the swingarm bolt? If so any info on how you did it is appreciated like what size socket, etc. Thanks.
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

Shadowjack
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Re: 82 Bagger

Post #22 by Shadowjack » Fri Nov 08, 2019 9:43 am

Pipe wrench

txtriathlete
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Location: Rapid City, SD

Re: 82 Bagger

Post #23 by txtriathlete » Sat Nov 09, 2019 10:35 am

Shadowjack wrote:Pipe wrench


I ended up just using a big hammer and punch.
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

txtriathlete
Cast Iron Member
Cast Iron Member
Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Re: 82 Bagger

Post #24 by txtriathlete » Mon Nov 11, 2019 5:32 pm

Got through most of the front end R and R over the past few days. Still need to put the brakes calipers back together. Found some fork tube extensions on Amazon for pretty cheap so gave them a try. Getting close to the stance I'm looking for. The wheel on the bike is not the one I'm using, I have an 83 mag to match the rear - but that one doesn't have a tire on it and I'm not ready to invest in rubber yet, so the old one will have to do for mock up purposes.

Image

I ended up missing the last bit of the pipes in the picture but they are about 3-4" off the floor now with the rear shocks in full compression. I found a nice set of fishtails I think will add to the effect. If I run them straight back off the headers and not tilt them up I can probably get the pipes another 2" lower and the bags lower in turn. But to go that route I will need to cut the mufflers and headers apart. I really, really don't want to do that, they are super clean and I see on Ebay good ones are approaching unobtainium prices. So maybe I can find a decent set of headers somewhere that will work and just use those instead of cutting mine apart.

Do GL1000 headers fit the 1100 heads? Seems they must as I have seen a lot of folks swap heads between 1000s and 1100s. So maybe I can go that route and save these pipes.

Beach bar handlebars are ordered. Between extending the forks and using wider (39") bars I'm not sure the stainless brake hose set I bought will work. May have to go with custom hoses and sell the ones I already bought. Trial and error I guess.

Front engine R and R next up, then a hard decision about carbs - keep the 4 banger rack or go with awesome weber twin stacks? And approaching having to decide on a headlight and turn signals. It's only money...
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

User avatar
Track T 2411
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My Album: http://www.ngwclub.com/gallery/v/wingmans/Track+T+2411/
Location: Prairie du Sac Wisconsin

Re: 82 Bagger

Post #25 by Track T 2411 » Mon Nov 11, 2019 9:35 pm

1000 headers will fit. '75-77 headers have the outlet angle more parallel to the ground, '78-79 are angled more upward. Both styles seem to tuck in closer to the frame of the 1100 than the stock exhaust.
"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.

txtriathlete
Cast Iron Member
Cast Iron Member
Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Re: 82 Bagger

Post #26 by txtriathlete » Mon Nov 11, 2019 11:24 pm

Track T 2411 wrote:1000 headers will fit. '75-77 headers have the outlet angle more parallel to the ground, '78-79 are angled more upward. Both styles seem to tuck in closer to the frame of the 1100 than the stock exhaust.


Sweet. I think I saw a set of 75-77s on ebay. Thanks!
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

txtriathlete
Cast Iron Member
Cast Iron Member
Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Re: 82 Bagger

Post #27 by txtriathlete » Mon Nov 18, 2019 4:24 pm

Had a "waiting parts" day today without a lot of other projects pending, so took some time to look at the rear fender and start making decisions about what might stay and go and what might need to be fabbed.

While test fitting the fender I noticed there are mounting holes in the fender right about where I need them in order to use the shock bolts to mount the fender. Very helpful!
Image

Initial cuts were to cut two slots for the frame rails (two rectangles on top of the fender)
Image

and remove the frame rails behind the shock bolts.

After flexing the fender wide, I was able to fit the fender over the shock bolts and get it more or less in its final resting spot. Full inflation (Ride height)
Image

And compression (stop/show)
Image

I still need to tidy up quite a bit - the sides are flexed way too far apart due to contacting the frame and parts forward of the frame like the battery box. But I should be able to cut sparingly and get it to tuck in with just a little trimming. The fender is long enough in front that I can use a bolt in the rear foot peg mount to add stabilization to the fender.

Center stand will be going away (sad panda) and I need to think about how low I can run the exhaust and not scrape. Right now they are about even with the bottom of the rim. But all in all its coming together.

And on another note, I test fit the rear signals/stoplight, and it looks like it to will go on with a minimum of fuss. Looks like I'll only need to drill one hole for the lower mounting screw.
Image
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold

txtriathlete
Cast Iron Member
Cast Iron Member
Posts: 73
Joined: Sat Aug 25, 2012 1:05 pm
Location: Rapid City, SD

Re: 82 Bagger

Post #28 by txtriathlete » Wed Nov 20, 2019 9:01 pm

Had some time today to work on the front end. Got the water pump housing put back together with the pump replaced. I painted the belt covers silver, they needed something, but not sure I like it. I think they will eventually get powder coated black along with the valve covers and floorboards. While waiting on paint to dry for the radiator fittings, started mocking up the front now that I have the headlight and brackets. I really like the way it turned out.
Image
The light bar and lower forks are all going to be black also.

Image

Image
The rear fender and compressed shocks are getting it to the stance I wanted. I like the clean lines of the back with the fender hiding all the business.

I think I may have a conflict with the fender and shocks tho. Upon further inspection it looks like the shocks are whats pushing the fender out.

Image

Image

Right now I'm thinking I might have to cut small peek-a-boo windows in the fender to let part of the top of the shocks protrude out. I think if I cut it right I can make it look good and add a little interest to the plain fender. The top of shocks are also going to be black so it shouldn't be too jarring. Unless I like the look of the chrome tops peeking out.

Time to start thinking about a seat. And I'm still thinking about a front fender. Maybe one from a Shadow ACE. And its getting to be time to figure out what carbs I'll use.
A few of my favorite things...
82 GL1100 Interstate - Current Project
99 Vakyrie Interstate - Daily (when the weather is nice) Driver
78 GL1000 Vetter - Restored to original - Sold
79 GL1000 Vetter - Refurbished as a Driver - Sold
78 GL1000 Naked - Project I never got around to - Sold
78 GL1000 "Old Gold" - The one that started me on this crazy path- Sold

95 20th Anniversary 1500 Wing - Sold
99 Kawi Drifter "Faux Indian" - Sold
03 100th Anniversary Harley Heritage Springer Softail - Sold


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