My Ulightning thing (aka update on Big Ugly)

[Phelan]

Made good progress today. Finally finished modding the firebolt tail to fit the Uly frame, albeit I also drilled and tapped 2 new holes in the frame flats to fit it. I trimmed the undertray a little to fit the extra wiring bulk, and installed my EBR turn signals (same as 2010 Buell) and 2010 XB R/S LED taillight. Gotta pull it back apart for various holes for mounting wiring, ECM, BAS, etc, as well as paint, but at least now that's out of the way. Tomorrow I'll put the top end and cams/cover back on the motor so I can reinstall the frame on the motor for now, so I can move forward with assembly. Hopefully I'll also have time to install the new steering head bearings (tapered roller bearing conversion) and replacement swingarm bearings.

 

[Phelan]

And the accent color is....

And yes I'm going to paint the tail lol

 

[Phelan]

I did get the motor reassembled. I got further along than this picture but I forgot to take pics. I was excited and eager to try out DK Customs rocker lockers, but upon reassembling the motor, I realized that I forgot to order them. Not wanting to wait to order some in, I made my own out of some .015" steel. So I should hear a bit less clatter in the top end .

 

[TPEHAK]

Looks very good. How much does it cost to rebuild the engine?

 

[Phelan]

Thanks! I am a mechanic and machinist and had full shop access when I did the machine work. I only bought the materials needed (few bearings and seals) and prepped and rebuilt everything myself. My cost reference would be nothing like someone else's tbh.

 

[Phelan]

Movin' right along! Here I got the swingarm, oil lines, and various bits mounted.

Then I bolted the frame and subframe onto the motor, and after this pic I bolted the rear shock as well. Normally you would want the exhaust mounted before attaching the frame, but I won't get the exhaust for another week or so, and I want to make this a roller. I can do a simple motor rotation to install the exhaust later.

Next, I moved to the front end. One of the pieces I've wanted to use for a while were these Rooke Risers. I cut the lower handlebar clamps off the top tree a while back, and today I filled in the original clutch cable guide hole and drilled 1/2" holes to mount the Rooke Risers.

These risers were made originally for Yamaha cruisers with 1 1/4" fatbars that tapered to 1". Since my OSX One fatbar is only 1 1/8" (standard oversize for 7/8" controls), I made shims out of some perforated steel tubing I had and I glued them in place to simplify installation.

Here's a mock up of the trees and risers.

And what's this?? We have a roller! I installed the new CR forks, put a front tire on the wheel, and mounted it up so the bike can almost stand on its own (still waiting on the SS kickstand). After this pic I also installed the front brake setup with new ceramic pads. I may source a shorter brake line, as the stock Uly brake line is now about 8" too long between the shorter suspension and shorter, straighter handlebars. The clutch cable is a little long, but plenty useable. Really excited to try see this build coming together.

 

[pur pony]

looking great Ross!

 

[Phelan]

Thanks Marc!

 

[NewmanS3]

Great job Ross, really loving that firebolt seat conversion.

 

[Phelan]

Thanks Newman!

I am so close now. I have a new name picked out, and want to keep the rest under wraps for now. I should receive the exhaust and last few bits next week. I'm going to great a new thread when I do complete it, and link it here. Thanks for watching .

 

[Phelan]

Things are moving slower than I'd like, because of various reasons- job, weather, later shipping on the exhaust, etc. But if I somehow manage to get out of jury duty tomorrow, I should be able to get it running tomorrow. In the meantime, here's a sneak peak...

 

[Dellinger]

This looks nice. I've been looking into an 1125R front end swap myself but can't get some of my questions answered. Does the steering lock work when using the CR or R upper and lower triples on the XB frame?

Finally a current thread.

 

[Chicknstripn]

Phelan! Where the EFF did you find the micron!!!!???
That's one of my only Buell regrets. I could have gotten one AT COST(I believe it was $600) in 2007 but thought that was too much.
I went with a jardine instead.
I'm a dumb ass. And a cheep ass.
If I knew then what I know now!
I like the way your build is going. And I totally understand SLOW progress!
Keep the updates coming!

 

[Phelan]

I'm using 1125 forks in the stock XB trees, so I honestly can't answer your question. If you go my route, keep in mind 03-04 XB and all SCG use smaller forks, and these forks won't fit in those trees. So only 05-10 non-SCG trees will work. 08-10 X trees will even give you more turning radius.

 

[Phelan]

Phelan! Where the EFF did you find the micron!!!!???
That's one of my only Buell regrets. I could have gotten one AT COST(I believe it was $600) in 2007 but thought that was too much.
I went with a jardine instead.
I'm a dumb ass. And a cheep ass.
If I knew then what I know now!
I like the way your build is going. And I totally understand SLOW progress!
Keep the updates coming!

Unfortunately, this one is a loaner, from a very good friend and client of mine. I'm looking for my own in the meantime to have hot coated black. I have first right of refusal if he does decide to sell it though.