Buying an Old Springer Fork ( DNA )

The style of the old springer fork is very nice. I really wanted to have this type of fork. So I went back to Motortechnica to ask some information about this fork. Unfortunately they told me that it is not possible to fit this kind of fork on every bike. We looked at it and I decided to go for it an buy it. Eventually I am very glad I buyed this fork because it gives the back a very nice old school look.

Getting the fork

The turning angle is not very big but a have found a way to make it bigger.

The turning angle is not very big but a have found a way to make it bigger.

First start up

A little movie of the first start up after the stripping and the rebuild.

Electrics: Part ONE

One thing where I always was afraid for is the electronics. I didn't have that much electrics in school and I really sucked in it :p. So I looked in the internet for as much information as possible. Really helpfull sites:

http://www.bikeexif.com/motorcycle-wiring

http://cyclesource.com/newsblog/?p=19223

http://www.electrosport.com/technical-resources/technical-articles/how-motorcycle-charging-system-works

http://www.colorado.edu/physics/EducationIssues/podolefsky/electric_motorcycle_howto_wiring.html

But the most help I got from this site ( http://www.rabiator.de/ ) it is a project site from Jürgen how also has a Yamaha Virago XV250. There I found really good plans of the electrics. With the bare minimum of basics of electrics I was able to rewire the bike and let it start. I had however help of my buddy Joachim. This was for me a milestone because I did know that if I can let it run again I can finish the project.

I welded the gas tank mount back myself. 

My buddy Joachim

Putting the engine block back in

After the welding of the hardtail was ready I really could start with the project. The most difficult part is done ( I hope :) ). Now I putting the engine back in ( Heavy as hell ).

Hardtailing: The actual welding

Later I decided that this part had to be very strong and good because of safety. Therefor I chose to let the welding do by a professional. I went with my project to the Old Garage ( https://www.facebook.com/theoldgaragecustoms/?fref=ts ). There I asked him to weld the hardtail to the frame. Afterwards this was a good choice of me and he did a very good job.

Hardtailing: Cutting and fitting the hardtail kit

First I tried to cut as least as possible material away to be sure I didn't do anything wrong. I wanted to weld the hardtail myself. So I puzzled a lot to make the best fit in frame and hardtail. 

Hardtailing: Buying the hardtail

The most difficult part of the whole project is by far hardtailing the Yamaha frame. I searched a lot on internet to find the cheapest, easiest and best way to hardtail my frame.

There are a lot of ready to the last gaiter button hardtails but not for my frame.

Hardtail for the Harley Sportster ( http://www.ebay.com/itm/TC-Bros-82-03-Harley-Sportster-Weld-On-Hardtail-Frame-Kit-Bobber-Chopper-Rigid-/161885784044 )
This is not the good hardtail for me.

Hardtail for the Yamaha XS600 ( http://www.ebay.com/itm/Yamaha-XS650-Weld-on-Hardtail-Chopper-Bobber-Frame-650-rigid-kit-xs-/351570366548 )
This was a long time my best option because I thought its for a Yamaha and it wil fit more Yamaha's than only the XS. I was very wrong about it and I realised it later.

Universal kit ( http://www.ebay.com/itm/TC-Bros-Universal-Weld-on-Hardtail-Hard-Tail-Kit-104-0011-/191706460497 )

Finally I thought I had found the ideal kit for my Yamaha. It is really the best kit for universal purpose. However I have totally no experience with welding so this was going to be very difficult. I always wanted to learn welding so I thought this is a very good moment to learn it myself. I bought a welding post and learned myself a little bit of welding BEFORE buying anything. However I really doubted about the succes rate.

So after the research I decided to go to a specialist. I went to http://www.motortechnica.be/ in Dentergem, a Harley Davidson specialist. There I met Barry the owner of the shop, a very helpfull and friendly man. I had a conversation with him and he told me the universal kit is very very difficult to use especially if you can't weld. So i stepped away from that plan. Barry searched with me for a new solution and we came up with this hardtail kit ( http://www.sportsterspecialty.com/frame-hardtail-weld-on-type-for-1982-2003-harley-sportster.html ). He thought this will fits best on my frame but wasn't 100% sure. I decided to buy it and go for it!

When I finally got it I tried to make a good plan in my head to fit it to the frame. I had to cut some pieces of the hardtail but also from my frame and I didn't want to make mistakes. I decided to do it piece by piece.