Sidebag hinges

Another thing that have been bugging me since day one was the poor way to mount the lids on the sidebags.

In the beginning the lid came off when unlocked, in the front it was just a tab that went in to a hole
and this was a bad idea from the beginning so after 30yrs of rattle it had become even worse.
So I saved the hinges from the Tourpack before I threw it in the bin.
With some tweaks the hinges was mounted and I had a fairly solid solution with a hinge in the front of the bag.
Next step is some of solution for it to stay open when unlocked, but more about that later.

  The Tourpack residues got new life

CV carb again

I had to do a cover for the "wire wheel" and solve a problem with a sloppy return spring on the mighty Dellorto carb so I had to go back to the trusty old CV for a season to pass technical inspection. (every other year here in Sweden)
This was a straight forward job. The CV had been working perfect before so it was just to remount it with all the old hardware, cables and airbox.

Seatpans

Two seatpans was made of fibreglass and epoxy.
This time I made them with the bike as a mould to get low profile and perfect fit.
I made two of them, one for a big comfortable dual seat and one to the sleek but still comfortable “Badland” style seat.
But the final job making seats of them was put to halt and will be done a later year.

I made two of those

The fifth winter (11/12)

This really became a middle year in the life of Swebagger but still some stuff was made...
And even this year the first spring run was made in the middle of the summer.

# Seatpans (again)
# CV carb again (a quick swap back to the CV)
# Sidebag hinges (Tourpack residues)

Windshield

After some sheet plastic hunting i found a piece that was ok, not dark enough to be honest but good enough. I used the old windshield as a template and used a regular jig saw to get the right form.
I had already made a lower windshield of the stock clear one that looked great, so I just had to copy that one to do my darker version.
To mount it I walked an extra mile, two sets with “Bar’ n Shield” licence plate mounting kits was bought.
I used seven of these eight “Bar’ n Shield” bolts to mount the windshield and it looked awesome.

Nice shade

The mounting hardware

Carb tuning

When all the hardware job was done with the Dellorto carb the tuning begun.
After some tips from a English company that sold me parts I was on the road.
I realized quite fast that I needed some help with the basic tuning but the sad part that none had any experience with it. So the only thing was to use books to become familiar with the Dellorto.

This book and Matt at dellorto.co.uk was a enormous help in this adventure

But after hours of reading books something was still missing, so the hunt for a Lambda/AFR meter begun. Quite soon I found a decent one to a great price. 

A Lambda sensor bung was welded in the rear pipe and the gauge was mounted in the fairing instead of the broken clock.

The lambdameter hooked up in the fairing.

And a lambda sensor in the rear pipe

Now I was ready for some serious tuning.

After a while with lots and lots of short test runs I had a Dellorto set-up that looked amazing and with reasonable driveability. The next step was to do the final tuning on the dyno.

On the dyno, at last

But It took untill autum 2013 before I got to do some dynoruns with the Dellorto.

Because I had to do a cover for the "wire wheel" and solve a problem with a sloppy return spring first. So I had to go back to the trusty old CV for a season to pass technical inspection, but now the problems are solved and the mighty Dellorto crowns the Shovel again.

But the best news was that the cool Dellorto was even better than the boring, mainstream CV !!

Turquoise -> CV vs Red -> Dellorto

New carb

One day I saw a picture of a Dellorto DHLA two throat carb mounted on a long intake and I was hooked !!
I soon found an old intake on eBay and when I got it home I started by de-chrome the dodgy chrome and then did some hard time by the polish wheel and eventually it got a new shiny life.

The carb hunt was up next, after a while I found one in a really bad shape that i got for a bargain.
It didn’t matter because I was to rebuild it completely so I went for it.
First stripped it down completely and then some glass blaster before it got all shiny inside bits and fresh gaskets.
Really expensive in the end but when I saw it mounted on the FLT together with the awesome shiny intake and the huge K&N filter with velocity stacks hidden under it was worth every penny I can guarantee.

The new carb adventure started with this mess...

...and ended like this, maybe the most awesome Harley carb setup in the history

And to get all hardware together became the easy part when looking back at this project.

Next step was o get it dialed in properly, not the easiest task I discovered.