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Sportster Project

Sportster Project

Build. Tinker. Ride. Trials and Tribulations (and good times) of my motorcycle projects and other garage tinkering. Learning and building things. Building, wrenching on, and riding Harley Davidson Evolution Sportsters, Big Twins, and anything else with two wheels. Currently working on restoring and preserving a 1988 Harley Davidson Sportster chopper. I also post information on other DIY projects I tinker on.




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  • 1988 Sportster
  • 1990 Sportster
  • 1992 EVO Big Twin
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  • 1999 Honda Shadow
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  • Other Stuff
  • Tested the rear brake bracket fit using the hardware supplied in the kit.
    1990 Sportster

    Sportster Hardtail Rear Brake Bracket…

    December 27, 2023 by Hersey
  • Checking Engine Fit after Welding the TCBro's Hardtail
    1990 Sportster

    Sportster Hardtail Progress…

    December 14, 2023 by Hersey
  • 1990 Sportster

    Cutting the Sportster in Half…

    December 1, 2023 by Hersey
  • TC Bros Sportster Weld-on Hardtail Kit
    1990 Sportster

    Measure 3157 times…

    November 27, 2023 by Hersey
  • Sportster Stripped Down Ready for the TC Bros Hardtail Kit
    1990 Sportster

    Hardtailing the 90 Sportster…

    November 25, 2023 by Hersey
  • Antique Motorcycle License Plate
    1988 Sportster / 1990 Sportster / 1992 Heritage Softail / 88 Swedish Style Sportster / vlog

    Registering an Antique Motorcycle

    August 30, 2021 by Hersey
  • Front Forks Reassembled on the 1990 Sportster
    1990 Sportster / vlog

    90 Sportster Leaky Fork Seal…

    August 25, 2021 by Hersey
  • All Balls Carburetor Rebuild Kit - Everything needed for a CV Carburetor Rebuild - Gaskets, Jets, Screws
    1990 Sportster / vlog

    Rebuilding the carb for the 90 Sportster…

    August 16, 2021 by Hersey
  • Harley Davidson Carburetor Cleaned and Ready for Rebuild
    1990 Sportster / vlog

    Cleaning the carb for the 90 Sportster…

    August 14, 2021 by Hersey
  • Sportster Project Build. Tinker. Ride.
    1988 Sportster / 1990 Sportster / 1992 EVO Big Twin / 1992 Heritage Softail / 1999 Honda Shadow / 2014 Street Glide / 88 Swedish Style Sportster / vlog

    Sportster Project YouTube Channel…

    July 20, 2021 by Hersey

Tag: weld

Sportster Hardtail Progress…
1990 Sportster 

Sportster Hardtail Progress…

December 14, 2023 by Hersey

Got the hardtail welded in. Looks pretty good. Not too much to say about it other than I think if went together nice. I am fairly confident my welds are good and will hold her together.

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Battery Tray Mount Repair…
88 Swedish Style Sportster 

Battery Tray Mount Repair…

May 14, 2021 by Hersey

On this 88 Sportster both of the mounts on the oil tank which the battery tray bolts to are broken. Forney Easy Weld 140MP to the rescue! Removed the oil tank, cleaned it up, and did a piss poor job of welding…

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Have a seat…
1992 EVO Big Twin 

Have a seat…

March 11, 2019 by Hersey

I thought I had an old Softail seat, but I don’t. I know I had one, maybe I sold it 🙁 I did have two touring seats, but neither of those would look right on this. A solo spring seat it is….

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Rear Fender… Mounted!
1992 EVO Big Twin 

Rear Fender… Mounted!

March 8, 2019 by Hersey

I have been in Vegas this week for a work conference, but before I left I was able to mock up is the rear fender. To get the fender mounted I needed to get the fender centered, weld a fender support bracket…

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Tank mounts… Mounted!
1992 EVO Big Twin 

Tank mounts… Mounted!

February 24, 2019 by Hersey

The Sportster style gas tank which came with my roller kit mounts to the frame from the underside and included a mounting kit. The tank mounting kit contained rubber grommets for vibration isolation, bolts, washers, spacers, and two 1/4″ steel mounts which…

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Welder…
Tools 

Welder…

February 4, 2019 by Hersey

I have a cheap flux core welder I got from Harbor Freight some time ago. It served its purpose – mostly just to tack things in place, no real “welding”. It quit working so I decided to upgrade and plan to practice…

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Tags

battery black brakes caliper carburetor chain cut cylinder engine exhaust fender frame garage gaskets gas tank hardtail Harley Davidson headlight heads honda shadow ignition intake iron butt jeep mount oil lines oil tank paint parts piston Primary project pushrods rear ride sissy bar Sportster start Street Glide tank TJ Brutal Customs valve weld wheel wiring

Links and Resources

  • Dime City Cycles
  • Deadbeat Customs
  • JP Cycles – Aftermarket Parts
  • CV Performance – Harley Carb Parts
  • 1992 EVO Project Budget
  • Tidewater Motorcycles – Local Shop
  • SportsterProject on Instagram
  • TC Bros Choppers
  • TJ Brutal Customs
  • XL Forum – Sportster & Buell Community
  • The Good Old Motorcycle Parts Company
  • Biker Direct – Aftermarket Parts
  • HD OEM Parts Finder
  • My 1990 Sportster Project Pinterest Board
  • Billet Proof Design
  • Lowbrow Customs Sportster Parts

Manual

If you own a 1986-2003 Sportster this is a must have manual.


Clymer Harley-Davidson XL/XLH Sportster
(1986-2003)
Maintenance, Troubleshooting, Repair

Recent Comments

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Categories

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Most Viewed Posts

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