Throttle assembly

Final assembly of the complete handlebar is something else than just put all the parts on for a mock-up.
The throttle assembly for example needed some TLC to work as desired.
And a throttle cable also had to be "made".
The only bolt on part was the clutch cable.
It was the clutch cable that made the decision to use Buell controls from the beginning.
The old Buells with Sportster engine have the right length and the right ends. My goal is to use OEM parts when it's possible.
So assemble the clutch cable was a quick job. Just route it nice and safe, secure it with some clamps on the way and mount the ends, done.

The throttle assembly I use is a old classic here in Sweden, made in Sweden.
A "quickthrottle, for peppy starts" as the old ads said.
A motocross and speedway assembly but also often used by youngsters on their mopeds.
But of course it needed some TLC to fit the Bombus specification.
Had to make a new thread to match the existing thread on the throttle cable.
I also made a cut in the housing so the throttle wire could be more easy to assemble.
Also the housing and the throttle tube itself got some griding and polishing inside to make the movement as smooth as possible.


The throttle cable

Cut it to apropriate length, put on a brass nipple and some solder

 Some heat and grinding later it looks like a OEM part. 
At least Bombus OEM. *Hehe*

The throttle assembly

The old dismantled OEM HD throttle cable.

The adjuster/bend will not be used

A cut along the threads to more easy mount the wire.

New threads to match the OEM threads already on the throttle cable

Testfit

The final build.

After some adjustments I got the throttle assembly smooth and without binding.

The throttle travel is very short so i definitely will have a peppy throttle response.

Oil hoses

Time to route the oil hoses.
With my slightly wider custom frame and the cam cover mounted it's more than a challenge to reach the oilpump.
So with help from some friends we carefully put the bike on its side.
By doing this and raising the lift to a more comfortable height the work went so much easier.

The patient up on the surgery table ready for treatment

Rear struts

The fenderstruts must do their job better then ordinary struts.
They not only supports the fender they also acts as mounting brackets for the rear light assembly.
I went for the "Colorado" from Highsider.
Really neat little pieces combining rear light, brake light and indicators in a small package. Just 40mm in diameter.
And on top of that is that they are also E-marked, a requirement to pass SFRO inspection.
But to complicate things I of course choose just the inserts, not complete units so making the housings was up to me.

Some pipe was bought, just big enough to accommodate the inserts.
And then fabrication started.

First I made two "washers" that acts as mounting surface for the lights. 

All bits required including the just made washers

Made them just so big so they would fit inside the pipe
and then some more measurements before I welded them to the struts. 

Next up was trim the pipe that would act as housing. 

Also a ton of measurement and fine grinding before I could put them "over" and weld them over the washers already welded in place. 

Last fabrication was to fill the open part. 

But before I did that I gave the opening an angle that made it look more sleek and then I cut a suitable bit of sheet metal and welded it over the now open, angled part. 

The housing mounted and one of the angled

The opening welded and the light test fitted.

Then some black paint and then install the inserts with double sided tape before the went on the bike again. 

Seat, the final

After a quick tour to the local upholstery shop Bullit Leather this little gem returned.
Really satisfied how it turned out.
The leather to cover the seat was a gift from my friend Viking Cycles.

The little black gem ready for Bombus Speedster

Looks nice together with the "stickerbomb" rear fender

Still looking good a step back

Seat, part two

Then some sort of device to secure the seat to the frame.
My choice was to use two hooks that went under the cross member in the front under the seat.
And in the back I use a kind of heavy duty "Velcro" from 3M called "Dual Lock™".
Next up was shaping, first bend the edges and then trimming the outline.
To simulate the thickness of the leather I put three layers of duct tape on the frame.
After that, the foam.
Glued the rebond foam to the pan, and then shaped it with a regular wood rasp.
Not the fastest way but with very much control unlike when you use something like a angle grinder.
And when I was satisfied with the shape I left it to Bullit Leather to cover it in black leather.
Bullit Leather is a local upholstery shop near my garage.
Always nice to support local businesses when possible.

The hooks to secure the seat in the front.

Glue the pieces of foam together on the pan.
Between the seat and frame I put three layers of Duct Tape to simulate the thickness of the leather

First some rough shaping with a knife

And the final result ready for the local upholstery shop, Bullit Leather.

Licence plate mount

One of those small easy to forget things that still is vital for the final build.
Some brainstorming and I went to action.
I took a bit of steel bar and some sheet metal.
Draw the outline of a licence plate, a LED light and a E-marked red reflector.
Both light and reflector are mandatory to be road legal.
After drawing the outline it just took a while with the angle grinder and file to get the plate mount ready.
Next up was the mounting bar.
Drilled a hole in one end and then bend the other end.
Some reinforcing in the bend and then weld the bar and the plate mount together, some paint, attach light/reflector and VIOLA!
The license plate mount was done.

The start pieces.

Some measurements, cuts and a bend later

Mockup with magnets to keep it together.
Still without the reinforcment welded in the bend.

Weld them together

And the final piece from the front with some black paint on.

And from rear without the licence plate but with blue tape instead to see the shape,
Haven't got the licence plate yet. It will take a while more until I´m there...

Rear fender

Hard to do temporary stuff when it still have to look reasonable and have a good function. 

The rear fender is one of those things right now, 

I don't trust it much to rescue me from the hard and unfair amounts of rain that often decorates the roads here in Sweden. 

So for now I went for the tiny fender I had. 

First some bondo and sanding to make it at least OK before I showered some layers with black paint over it. 

Next step was new to me, vinyl wrapping. 

I bought a "sticker bomb" vinyl sheet at eBay for this purpose. 

Slow and with determination I started with the task.
WOW, what a shitty vinyl wrap that was. 

I'm no stranger to crappy Chinese stuff from eBay, but this was really another level of crap. 

I went for it anyway and after a while I had a sticker bomb fender that actually looks OK.
Or as a wise man stated: "Good looking from far, but far from good looking"

Caught by the moment I continued with the air cleaner insert, and that turned out really god as well.

The black fender and the stickerbomb vinyl sheet when

I still was happily unaware of the nightmare to come

Wrapping in full swing

And the result. From a distance it actually looks really good.

Most of the fender will be covered by the seat anyway.