1981 Ironhead Bobber Rebuild

Lloyd from Mechanicville, New York, United States made available these pictures of the rebuild of his Harley Sportster Bobber / Short Chop which has a 1981 Ironhead Engine in a hardtailed 1975 Sportster frame. The springer is a stock length DNA for big twins.

Starting Point: 1975 Harley Sportster Bobber

Lloyd sent us a picture of his Bobber in the state it was in when he bought it off eBay a couple of years ago:

Lloyd: "The welds on the hardtail were rough, rewelded and blended The painter, Johnny D of Outrageous Paint blended all the welds on the frame very smooth, hot rod black base coat clear coat."

Rebuild: 1981 Ironhead Engine in 1975 Frame

1981 Ironhead Rebuild Specifics

Lloyd gave us the following list of activities and modifications he did on his Harley Sportster Short Chop / Custom Bobber:

• Fit a 1981 motor in a 1975 frame;

• Had to modify frame under the motor so motor would fit in;

• Made it so it is now a left side shift, right side brake;

• Made a transfer linkage for rear brake to work with forward controls;

• Cut out center of frame, 2 ugly tubes and welded in a single tube;

• Oil tank and filter are mounted on the new single tube;

• Made new mounts to fit aftermarket oil tank;

• Relocated the oil filter to mount over battery;

• Oil cooler was on bike when I bought it so I reused it;

• Made the battery box and license plate taillight mount;

• New DNA big twin front end with new brake and wheel;

• Stock rake on frame;

• Fit a plate on frame under seat to close up area to hide all the wiring;

• Hid all the wiring by running it through the frame tubes;

• Cut rear fender from a blank and made the fender struts;

• Real alligator skinned seat;

• Original Harley rear wheel with new brakes, sprocket and drum;

• Wiseco 10:1 pistons .010 over;

• New Barnett clutch;

• The exhaust pipe is from Twisted Choppers;

• All new cables,grips, just about everything was replaced;

After Rebuilding: 1981 Ironhead Custom Bobber

Lloyd also sent us a bunch of picture of his Custom Bobber after he finished the rebuilding:

To view all pictures of Lloyd's 1981 Custom Sportster Bobber: CLICK HERE

(January 2010)