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techtalk:ref:body30k [2019/06/29 01:21] hippysmack created |
techtalk:ref:body30k [2024/01/09 21:19] (current) hippysmack |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
| - | ====== REF: Body Parts - Sub-01K ====== | + | ====== REF: Body Parts - Sub-30K ====== |
| \\ | \\ | ||
| ====== Shifter Mods ====== | ====== Shifter Mods ====== | ||
| - | 50bmg shifter: \\ | + | ====== Pegs ====== |
| - | The shoulder of the casing was cut off with a bolt epoxied into it. ((photos by DaytonaSportster of the XLFORUM http://xlforum.net/forums/showthread.php?t=1182952&page=3)) \\ | + | |
| - | |{{:techtalk:ref:body:shifter_ped_mod_1_by_daytonasportster.png?direct&300|}}|{{:techtalk:ref:body:shifter_ped_mod_2_by_daytonasportster.png?direct&300|}}| | + | |50bmg shifter: The shoulder of the casing was cut off with a bolt epoxied into it. ((photos by DaytonaSportster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-photos-videos/120968-lets-see-the-brass/page3?t=1182952&page=3))|| |
| + | |{{:techtalk:ref:body:shifter_ped_mod_1_by_daytonasportster.png?direct&250|}}|{{:techtalk:ref:body:shifter_ped_mod_2_by_daytonasportster.png?direct&250|}}| | ||
| + | |Skateboard wheel mounted to the shift lever. ((photo by jonv of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/199305-primary-oil-leaking-from-primary-case#post4386657))| | ||
| + | |{{:techtalk:ref:body:skateboard_wheel_on_shifter_lever_by_jonv.jpg?direct&300|}}| | ||
| + | |||
| + | ====== Heel / Toe Shifter ====== | ||
| + | |Hand Built Heel / Toe Shifter ((photo by Jolly Rogers of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-photos-videos/69053-close-ups/page53?t=461674&page=53))| | ||
| + | |{{:techtalk:ref:body:hand_built_heel_toe_shifter_by_jolly_rogers.jpg?direct&250|}}| | ||
| + | |||
| + | ===== Homemade Heel / Toe Shifter ===== | ||
| + | Article by rasaine of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/89297-custom-made-heel-toe-shifter?t=716217)) \\ | ||
| + | |||
| + | These were built for a 2009 1200C. \\ | ||
| + | You may have to do some measurements and fitting on different year models but the concept is the same. \\ | ||
| + | |||
| + | |||
| + | This design will not work on the Mid Controls as there is no connecting rod. \\ | ||
| + | Mid mount controls have a shift lever that mounts directly on the splined shaft coming out of the transmission housing. \\ | ||
| + | However, you may be able to study, measure and come up with a design. \\ | ||
| + | |||
| + | Below are 2 different versions of heel / toe shifters for forward controls homemade by rasaine. \\ | ||
| + | With the second version, the foot rests 100% on the foot peg and doesn't touch either the shifter peg. \\ | ||
| + | To shift, you don't have to lift your foot at all. \\ | ||
| + | You just rock down on the Toe (down shift) or Heel (up shift). \\ | ||
| + | The Sportster foot pegs are wide. \\ | ||
| + | So during normal riding, the foot is fully out on the foot peg. \\ | ||
| + | And the shifter pegs do not interfere with any position you put your foot in. \\ | ||
| + | <blockquote>When shifting I slide my foot to the inside of the foot peg and am actually resting partially on the chrome hinged area of the peg. | ||
| + | </blockquote> | ||
| + | |||
| + | **Download the full instructional PDF here**: {{ :techtalk:ref:body:homemade_heel-toe_shifter_instructions_by_rasaine.pdf |}} \\ | ||
| + | These instructions are valid only for Forward controls on a 2004 – 2009 (2010??) Sportster. \\ | ||
| + | The unit I made for Terp84Alum required some modification and redesign due to the different footrest shaft used on the non-rubber mount bikes. \\ | ||
| + | Unfortunately when I converted the drawing to a PDF file, the templates do not print out true to size. \\ | ||
| + | They are close, but will need to be enlarged slightly to be accurate. \\ | ||
| + | The Shift Peg Rail is 8-1/2" end to end. \\ | ||
| + | The printed measurements are correct. \\ | ||
| + | |||
| + | **Tools**: \\ | ||
| + | Drill Press, Band Saw, and a bench mounted Belt Sander (other than common hand tools). \\ | ||
| + | And a LOT of "elbow grease" (12 - 16 hours of labor.) \\ | ||
| + | **Parts**: \\ | ||
| + | The 1/4" aluminum was $12.22 - ordered from McMaster-Carr (#8975K713). \\ | ||
| + | Bolts were less than $5.00. (Lowes). \\ | ||
| + | |||
| + | **Materials**: | ||
| + | The shifter is constructed from a single piece of 6061 Aluminum, 2” wide, by ¼” thick by 36” long and cut it into 7 pieces. \\ | ||
| + | * (2) at 8 ¾” for the main shift rail. | ||
| + | * (2) at 4 ½” for the shift rod lever. | ||
| + | * (3) at 2” for spacers. | ||
| + | |||
| + | I determined the correct pivot position for each piece and drilled a 15/16” hole through each of the 7 pieces. \\ | ||
| + | This is the correct size hole to allow the Nylon bushing from the factory shift lever to slip into and line everything up. \\ | ||
| + | The order of assembly: \\ | ||
| + | * Outside spacer. | ||
| + | * Two Main shifter rails. | ||
| + | * Two shift rod levers. | ||
| + | * And two inside spacers. | ||
| + | |||
| + | <blockquote>All pieces were cut to shape and sanded smooth before assembly. \\ | ||
| + | I used a Band Saw with a metal cutting blade. The soft aluminum cuts very easily. \\ | ||
| + | I matched the 2 main rails and the 2 shift rod levers to each other by clamping them and sanding the edges with a bench belt sander. \\ | ||
| + | Then I matched the two inside spacers to the shift rod lever the same way. \\ | ||
| + | Once I was satisfied with the shape, I sandwiched the pieces together by drilling holes for five 10-24 x2” Stainless Steel bolts, inserted from the rear. (See rear view). \\ | ||
| + | I only threaded the two Main shifter rails and outside spacer. \\ | ||
| + | All the other pieces are slip through for the bolts, and the inside spacer is countersunk to allow the bolt heads to be flush. \\ | ||
| + | Bolts are inserted with Loctite. \\ | ||
| + | The bolt ends slightly stuck out from the outside spacer, I cut them off flush with a Dremel cut-off wheel. \\ | ||
| + | Then I drilled Lightening holes. \\ | ||
| + | Finally everything was sanded with 220 wet sand, then polished. ((photos by rasaine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/89297-custom-made-heel-toe-shifter?t=716217)) \\ | ||
| + | </blockquote> | ||
| + | **Version 2**: \\ | ||
| + | |{{:techtalk:ref:body:custom_made_heel_toe_shifter_1_by_rasaine.jpg?direct&300|}}|{{:techtalk:ref:body:custom_made_heel_toe_shifter_2_by_rasaine.jpg?direct&300|}}| | ||
| + | |||
| + | |{{:techtalk:ref:body:custom_made_heel_toe_shifter_3_by_rasaine.jpg?direct&300|}}|{{:techtalk:ref:body:custom_made_heel_toe_shifter_4_by_rasaine.jpg?direct&300|}}|{{:techtalk:ref:body:custom_made_heel_toe_shifter_5_by_rasaine.jpg?direct&300|}}| | ||
| + | |||
| + | Here version 3 with refinements. \\ | ||
| + | This is a more sleek and refined finish. \\ | ||
| + | The shift peg rail and shift lever arm are now made of 1/2" aluminum and are not laminated. \\ | ||
| + | The overall laminations are reduced from 7 to 4. \\ | ||
| + | The orientation of the shift pegs to the foot rest is the exact same as version 2. ((photos by rasaine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-accessories/89297-custom-made-heel-toe-shifter/page2?t=716217&page=2)) \\ | ||
| + | |||
| + | **Version 3**: \\ | ||
| + | |{{:techtalk:ref:body:custom_made_heel_toe_shifter_6_by_rasaine.jpg?direct&300|}}|{{:techtalk:ref:body:custom_made_heel_toe_shifter_7_by_rasaine.jpg?direct&300|}}|{{:techtalk:ref:body:custom_made_heel_toe_shifter_8_by_rasaine.jpg?direct&300|}}| | ||
| - | \\ | ||
