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Harley Riders USA Forums » Harley Davidson Motorcycle Models » Custom and Special Construction » Street Bob frame build


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Old 07-07-2011, 10:01 PM Top   #1 (permalink)
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Default Street Bob frame build

So the motor is out now and time for a new thread on this build coz I lost the last one

Going to chop this up a fair bit, swap out a lot of metal & lighten the whole structure. Plus as I don't need to worry about production lines and ease of assembly I can stiffen the frame up at the same time.

The welds and general finish are nasty also. So every weld will be re-done & every casting will be shaved and shaped.

First job is to DC/plasma off the big bits I don't want then send it off for blasting.

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Old 07-07-2011, 10:04 PM Top   #2 (permalink)
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what're you building a unicycle?

looking forward to seeing your craftsmanship
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Old 07-08-2011, 11:51 AM Top   #3 (permalink)
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caNt wait to see how this turns out...if u wanna send me ur tank in the mean time ill take good care of it
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Old 07-08-2011, 01:07 PM Top   #4 (permalink)
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so its gone off to blasting today but first i cut off a bunch of crap,, this is not the last of the shaving, but i thought i would hack off the obvious pieces pre blasting..



and Paul,, the tank still has many hours left in it !:


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Old 07-08-2011, 03:25 PM Top   #5 (permalink)
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Take the Street Bob, do whatcha will with her, you Doctor Frankenstein....

but PLEASE be gentle on that innocent little blue rocker.

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Old 07-08-2011, 06:48 PM Top   #6 (permalink)
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Uh...oh...now you done it ....Nothing screams like a painted frame ...
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Old 07-08-2011, 10:32 PM Top   #7 (permalink)
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We've only done lights, bars, rear fender & seat on that blue rocker... So it's ok , still breathing
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Old 07-10-2011, 11:02 AM Top   #8 (permalink)
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problems with the diks at the blasters, so got the frame back and set the final position of the tank,, then took a shot through the old filler hole showing how little tank is left

there is a huge amount of welding to do on this mutha

i am also going to make a billet sump with a cutout towards the rear to flush mount the regulator and keep it off the front (note the brackets already gone), however the loss of capacity needs to be dealt with so i am swapping out the front downtubes of the frame for DLC coated Stainless sealed tubes and will run an extra quart of oil in them, fed straight out the front the the oil filter mount,,,,



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Old 07-10-2011, 11:22 AM Top   #9 (permalink)
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Why not just use the old frame to build a jig.........
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Old 07-10-2011, 12:05 PM Top   #10 (permalink)
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we have a multi jig table,, i can build anything,,

sorry,, but you got me confused there, this is a Stock Modified build !
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Old 07-10-2011, 01:15 PM Top   #11 (permalink)
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A jig so you can keep the stock neck, backbone, bracketry, shock mounts, etc... and mandrel bend some DOM to replace the tube-cast sleeve-tube transitions. Just a thought.
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Old 07-10-2011, 02:08 PM Top   #12 (permalink)
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the frame will be on a jig for cutting the front downtubes out, you need to do that to hold it all in line.. unless you weld braces to it,, but we have a very cool German table at the shop and you can pretty much jig anything ..

i am replacing the rear shock mounts and replacing the downtubes to oil carrying stainless ones.

the rest has to remain, it needs to be tidied up and proper welds put in and detailed etc,, but the headstock and basic geometry has to be stock,, thats the rules.

if it were me, i would ditch the headstock and spine,,
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Old 07-10-2011, 04:10 PM Top   #13 (permalink)
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Whats gonna be left of the street bob...jut the vin!?! man ur takin it to another level...amazing!
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Old 07-10-2011, 07:16 PM Top   #14 (permalink)
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Peeking in ...
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Old 07-10-2011, 10:18 PM Top   #15 (permalink)
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Pretty much just the headstock & maybe the spine will be left, but tidied up and detailed. The Stock Modified rules are getting tighter about how far you can go before you get put in freestyle. Over here the Mod class is seriously tight with only a few votes separating the top 7 builders, so I wanna keep in it, way to much fun
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Old 07-16-2011, 12:08 PM Top   #16 (permalink)
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ok, so kind of a good thing i didnt get the frame blasted as it would have been a total waste of time,, after a lot of figuring out i found that the only part of the OEM setup i can use is the sub frame,, so here is a shot of what i am going to build from and a shot of the proportion of the frame thats toast:





so today was full of cutting the shit outta things,, this was my efforts to get the tank right for this build:



this is the start of the detailing needed on the kept part of the frame,, the front and rear castings need cleaning up and then half round welded in to complete the section and make it look half decent :



finally, before i cut the frame up, every single relevant point was mapped out and logged into the CAD system from our jig bench:

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Old 07-16-2011, 04:44 PM Top   #17 (permalink)
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Never seen a bike so chopped up before ...
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Old 07-16-2011, 10:15 PM Top   #18 (permalink)
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The scary part was the tank, coz it just wasn't working out for me and I kept cutting it trying to find the shape. I have probably 15 hours in the tank already and it was looking like a pile of sliced up crap heading for the bin

Took out a 40mm section down the middle, about 120 off the tail and sectioned a 50mm wide strip out the sides.

Then tacked it all back tougher and it started to look like something. So I cut the rear curves off a fatboy tank and tacked them on.

Right now it's like a midget Fatbob tank from the side and some weird fckin thing from the top so I am stoked, I know where I am going.

I got to cut the headstock off the frame and re- use it as it carries the VIN and this is all about "Stock Modified "
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Old 07-17-2011, 06:42 AM Top   #19 (permalink)
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You sure aren't afraid to rip some shit up, huh Pete?
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Old 07-17-2011, 01:19 PM Top   #20 (permalink)
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omg what ya doin' now ?? Gonna be cool to see the end product. Is there any tests got to be made on frame strength..I mean wherever you got to take it to get an official safety stamp ?? ..is it going to be a one off ?? Can standard parts be fitted like the tank etc or will everything be custom made
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Old 07-17-2011, 01:24 PM Top   #21 (permalink)
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omg what ya doin' now ?? Gonna be cool to see the end product. Is there any tests got to be made on frame strength..I mean wherever you got to take it to get an official safety stamp ?? ..is it going to be a one off ?? Can standard parts be fitted like the tank etc or will everything be custom made
i will show you through this thread how we weld the frame back together,, its all custom, even the headstock,,

as for strength, i share a unit with one of the best welders in the country who is also encyclopaedic in his knowledge of metals and how to stick them together. As most of the new frame is going to be Stainless we are TIG welding it to stock with several passes using diff filler rods each pass.

I am building this for stock modified so the majority of parts are going to be Harley as i think thats the spirit of the AMD competition. There are Companies who just buy 60K + worth of bolt on crap from RSD or PM,, get Image Design (the best custom painters in the world) to slap on an ultra trick paint job and call it a custom

to me its bollox,, this build will be 100% hand built, hand machined and 100% designed by us..

these are very early days, i do know how this build will go, i have it all drawn up and will run it out fully here for your critique
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Old 07-17-2011, 01:35 PM Top   #22 (permalink)
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ok call me a doughnut...explain more.. AMD competition..where and when,what country ? And its a build for your entry at stock/modified..
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Old 07-17-2011, 01:37 PM Top   #23 (permalink)
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its a world wide comp,, AMD are the organisers and it culminates at Sturgis ( in a couple of weeks time)

we got a 3rd with blackbird in the euro heats

so i kinda learnt a bit and i have a build in my head that i am hoping may do better

and yeah,, stock modified is the class i want to win first before we move on to freetyle
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Old 07-17-2011, 01:48 PM Top   #24 (permalink)
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Good luck
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Old 07-17-2011, 07:03 PM Top   #25 (permalink)
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Why don't you just cut it up a little? I mean it looks like you could do a few more cuts on the tank. At least one more.
Im curious to know what fillers you are going to use on the frame for all the passes.
Post pics and details.
And hurry the fek up
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Old 07-17-2011, 08:34 PM Top   #26 (permalink)
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whats the projected competion?
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Old 07-17-2011, 10:19 PM Top   #27 (permalink)
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Completion date is Feb 2012

Sounds far off but i feel under pressure already as the motor is getting hit with the grinder/welder also and so much other shit. The handlebars are gonna take ages to mill on their own let alone this fckin frame.

Rob, my welding Buddy, runs a fckin insane pulse TIG. He bought the model he's got because he can manually programme every single variant on the pulse, or double pulse or whatnot. The sound when he's welding some shit up is totally fckin weird!

He's also taught me MIG properly now, I never realised how bad I was

Will post up pix and also details on how we are gonna hit the 38mm 316 downtubes.
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Old 07-19-2011, 11:09 AM Top   #28 (permalink)
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ok so plans change,,

fact is i am going to build this Dyna for the Freestyle class and re-work Blackbird for stock modified

this means i am going to make an entire frame from scratch, only it will be available as a product so will be able to fit most stock Dyna parts.

anyway, i am going to make it from Chrome Moly with 316 stainless downtube & a 316 headstock,, this means some complicated joins and welds,, there will be stainless slugs/spacers between each join in the frame and the weld will be using several passes with 309 filler first and then 312,, the objective is to blend the materials and then weld stainless to stainless..

thats basically it,, i have the frame on CAD, am now searching for the size tube i need and then can finish a full 3D CAD drawing.. this then goes to the tube benders where they bang out each of the rails needed..

meanwhile i turn out a 316 headstock and mill into it our logo etc

and,, uhmmm,,, then the fun starts

will post it all as i fuck up

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Old 07-19-2011, 11:12 AM Top   #29 (permalink)
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ok so plans change,,

fact is i am going to build this Dyna for the Freestyle class and re-work Blackbird for stock modified

this means i am going to make an entire frame from scratch, only it will be available as a product so will be able to fit most stock Dyna parts.

anyway, i am going to make it from Chrome Moly with 316 stainless downtube & a 316 headstock,, this means some complicated joins and welds,, there will be stainless slugs/spacers between each join in the frame and the weld with be using several passes with 309 filler first and then 312,, the objective is to blend the materials and then weld stainless to stainless..

thats basically it,, i have the frame on CAD, am now searching for the size tube i need and then can finish a full 3D CAD drawing.. this then goes to the tube benders where they bang out each of the rails needed..

meanwhile i turn out a 316 headstock and mill into it our logo etc

and,, uhmmm,,, then the fun starts

will post it all as i fuck up
Way to go Bro
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Old 07-19-2011, 11:30 AM Top   #30 (permalink)
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Post a pic of the 3d cad drawing. That would be cool to see
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Old 07-19-2011, 11:36 AM Top   #31 (permalink)
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the 3D should be done in the next few weeks,, My Bud Trevor runs a pretty major CAD system and i am relying on his help...

will post it up
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Old 07-19-2011, 11:54 AM Top   #32 (permalink)
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Originally Posted by sk8rod View Post
ok so plans change,,

fact is i am going to build this Dyna for the Freestyle class and re-work Blackbird for stock modified

this means i am going to make an entire frame from scratch, only it will be available as a product so will be able to fit most stock Dyna parts.

anyway, i am going to make it from Chrome Moly with 316 stainless downtube & a 316 headstock,, this means some complicated joins and welds,, there will be stainless slugs/spacers between each join in the frame and the weld will be using several passes with 309 filler first and then 312,, the objective is to blend the materials and then weld stainless to stainless..

thats basically it,, i have the frame on CAD, am now searching for the size tube i need and then can finish a full 3D CAD drawing.. this then goes to the tube benders where they bang out each of the rails needed..

meanwhile i turn out a 316 headstock and mill into it our logo etc

and,, uhmmm,,, then the fun starts

will post it all as i fuck up

Pete, You are a FCKIN' Wild Man !

But Lord knows ya' do awesome work.



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Old 07-19-2011, 02:39 PM Top   #33 (permalink)
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we have a multi jig table,, i can build anything,,

sorry,, but you got me confused there, this is a Stock Modified build !
I see..........
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Old 07-19-2011, 02:44 PM Top   #34 (permalink)
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things change

ya see something was pointed out to me by a good friend, when i was up at his workshop yesterday
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Old 07-20-2011, 09:47 AM Top   #35 (permalink)
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things change

ya see something was pointed out to me by a good friend, when i was up at his workshop yesterday

And.................


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Old 07-20-2011, 11:52 AM Top   #36 (permalink)
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and he is a very wise bloke who knows a lot about the whole business and he was bang on with his opinion
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Old 07-21-2011, 09:08 AM Top   #37 (permalink)
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Dyna Bagger!!!!!! Now you will have to work on bagger SK8

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Old 07-21-2011, 10:28 AM Top   #38 (permalink)
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i aint talking to you also
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Old 07-21-2011, 02:51 PM Top   #39 (permalink)
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Thats the new dyna chop kit bike ,, those bags or stock tool boxes that come equipped with a saw,, welder ,,and trash bags ,,
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Old 07-21-2011, 04:51 PM Top   #40 (permalink)
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Dyna Bagger!!!!!! Now you will have to work on bagger SK8

I'm putting my bike on craigslist/ebay right now! I want one of those...
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