EFI cave

To solve the issue with a dry, safe place for all new electronic gadgets that comes with Electronic Fuel Injection something had to be done.
The non used greasy, dirty space under the seat became my target for this.
I had to fabricate a "front wall" and a "floor" to make it suitable.
The "floor" was needed to protect from the smudge from the chain and to mount the MAP sensor. The "front wall" to avoid engine heat and road dirt and to mount relays and fusebox.
The ECU found its place on the inside of the OEM plate for fuses and connectors.
Down in the bottom of the cable cave I fitted the fuel pump. The V shaped cross member between the frame rails was after some hard massage a perfect place for the fuel pump.
A very snug, but big enough place.
But more about the fuel pump/fuel system later.

Testfit of the ECU,  "floor" and "wall"

Fuel pump wired for test and plumbed ready 

to get some hose clamps and get mounted.

The gadgets in their final positions 

with the fuel pump in the bottom.  

The "cave" wired and pump running for the first time 

Noseart

It ain't just wrenching in the Speedshop, the eye also must have some attention. I have thought about a classic piece of "noseart" on the fairing for a long time. Was thinking of painting it but time went and nothing happened.
So it was time to realize that if I wanted the noseart I was dreaming about I had to seek help.
I made a rough sketch to get the proportions right then my friend Jimmy at Skylt & Gravyr Ateljén took over and made really great looking vinyls for me to attach.

The rough sketch

 Fresh from Skylt & Gravyr Ateljén

 And mounted on the FLT's mighty fairing

MAP sensor connection

Next part to get a ride in to the new century was the long vintage intake manifold. To handle petroleum/air mixture post Y2K there must be a air nipple to connect the hose from the MAP sensor (Manifold Absolute Pressure) in the manifold.
A dedicated spot in the manifold did the job easier.

The manifold ready for conversion

Followed by drilling and threading

And the final job ready to go back on the bike

A previous job to the manifold was exposed when it was dismounted. 

The top mounting thread was gone when I bought the old intake. 

I made a thick steel plate and bolted to the intake and then made a new thread all the way through both the new fresh steel and in to the vintage cast aluminum. 

So now the old intake can live on for many more years. 

Injectors

The first modification of the throttle body was for the injectors.
It was originally attended for mechanical injectors so some machining had to be made to fit the new generation electronic injectors. These new injectors was kindly donated to me by Deep Valley Workshop. So after some drilling, milling and grinding they fitted like they was originally intended to fit the vintage little gem.

Throttlebody

A fairytale with so many stages.
This long petroleum supply story began when I first saw a picture of the amazing looking long intake for the Shovelhead. I instantly fell in love ! Then the almost never ending story with the Dellorto dominated my driving and Speedshop time. This money consuming project went from dream to almost a nightmare. After so much money and time I had a bike that didn't run under 2000 rpm and not over 3000 rpm. Driving it was truly a challenge.
Without all the help from Matt at Eurocarbs this have journey had been a disaster from day one but there I got help and comforting words and parts  many, many, many, many  times.
But the mighty Dellorto got the last word, the Dellorto(this?) don't want to feed a Harley engine, Period!!

Thoughts about EFI begun way before this nightmare, but really took off when I found a pair of vintage Tecalamite Jackson mechanical throttle bodies at eBay.
The nice thing with those throttle bodies is that they are direct replacement to Dellorto/Weber/Solex carbs and this solves many installation problems. And I can still keep the mighty look I fell in love with in the first place with this application.
And the saga begun for real when I opened the box...

Signs...

My life ain't just the Speedshop, I also need to keep the cashflow balanced.
The money can't just roll out when buying parts for all the toys in the Speedshop so a day job is required.
And to save up the extra cash a brought lunchbox is one way to save up.
But a sign that I'm on the right path revealed itself one day in the lunch box...

Intake Air Temperature

Another thing that needs to be monitored is intake air temp.
First made a hole in the air filter bracket.
Then I welded the supplied stainless bung with the TIG. A not so challenging task but it had to be done. And after that it was just to thread in the IAT sensor.

Cylinder Head Temperature

More sensors. This time the CHT (Cylinder Head Temperature) sensor was next in line. The bike actually came with such sensor when new.
But now it was time to upgrade it more post millennium standard so the EFI system get the input it needs.
Autometer had a sensor that seemed to fit, so I ordered one from US.
When it arrived it was just what I have been looking for.
But the mounting hardware was not solved.
I made a aluminum spacer and than a nut with 1/8" NPT thread.
It paired up nicely with the stock hole in the rear cylinder head.

Size comparison

The nut made and ready for assembly

The final mount

Fuelrail - the end.

The Fuelrail didn't turn out like I wanted so another one was created, but this time I put much more love, time and effort. And now it turned out great.
A quick tour to get it zinc plated to protect it and give it the shine it deserve.

Fuelrail - the beginning.

This project became longer and more labor intensive than I hoped for.
I started with some square pipeing and bungs. Actually the square piping I had over from the dog cage project and the two bungs I made in my lathe.
And it started like this.

The main unit.

First job with the injection system was already made when the project went from Sportster to Bigtwin. Buying the EFI system.
I bought the system for the Sportster but when I ordered it I bought another wireharness. Just in case for the Bigtwin and that day came faster that expected.
I went for the DIY open source EFI system, Megasquirt.
This system have a quite large ECU so I went for the already assembled smaller version, Microsquirt.

The eighth winter 14/15

The eighth winter was originally intended for my new project, a custom Sportster build.
But things happens and friends pushed me in other directions.
So this winters lineup are for the old Shovelbagger:
# Completing the seat.
# "Noseart" on the fairing.
# And the main project, EFI.
It was time to take my old comrade in to the twenty first century with some Electronic Fuel Injection.
The EFI job have so many stages so each one makes a project of its own.
The updates will not always be in the right order either.