Throttle arrangement

To have a hardware adjusted idle and a good enough return spring something had to be made.
I took the return spring from a Buell throttlebody I had in the shop. But first I made a nylon bushing for the spring and shaft and then a bracket to hold the idle screw and stop screw for throttle travel.
Many templates of both cardboard and Pepsi can was made before I started with the real pieces. But soon enough I had some pieces I was satisfied with so I just welded them with the TIG. Drill holes, tap and some screws, some grinding and I had a throttle arrangement.

Buell return spring and home made bushing

Template time for the bracket

Bracket in the works

Welded and ready for some cosmetic grinding

( Yes, I was LOW on gas that day)

Final bracket

TPS

To get the throttlebody in to the new millennium a Throttle Position Sensor, TPS was required. I had a Buell throttle body with a TPS in the shop already so why not use that one. First I made a bracket to fit the TPS to the throttlebody. Then it was time to adapt the shaft to fit the TPS.
A hole had to be drilled dead center of the shaft to accept a small pin to turn the TPS. And finally a new connector was attached to the TPS.

The bracket

TPS test fitted

The drilled shaft

Dead center

Not to shabby consider I did it with a low buck asian drillpress.

New connector on the TPS

The seat

Another project this winter is a new seat.
Made the seat pan from scratch couple winters ago but the stroke and other projects have made this a low priority project.
But this winter it looks like the seat will be reality.
First some base shaping of the seatpan, then glue the foam to the pan, shape it and finally cover it.
Sounds easy and simple....in theory.
But everything is done besides cover it and it looks like this time I'm not doing it myself.
Hate to depend on others, like to do all my stuff by myself.
But this time it might be a exception.

Here is the raw seat pan I made from scratch with fiberglass and epoxy.

I had to modify the rear mount for clearance and I also put permanent metal threads for the mounting hardware.

Front mounting hardware

Shaped seat foam

I glued the foam to the pan and used tape to fixate when the glue cured.

Then some shaping and it turned out nice I think.

Ready for vinyl or leather cover.

Fuel system

The added fuel pump needs more stuff to distribute the yummy fossil fuel.
First some thinking about routing alternatives and for the regulator.
Than I had to buy quality hoses and a pressure regulator.
And after some routing of hoses and brackets it looked like this before the tank was installed.

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.