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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:

Image of 1975 Harley Sportster Bobber.

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

Photo of 1981 Harley Ironhead Engine in Hardtailed 1975 Sportster Frame with DNA Big Twin Springer by Lloyd.

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;

Photo of 1981 Harley Ironhead Engine in Hardtailed 1975 Sportster Frame with DNA Big Twin Springer by Lloyd.

Image of 1981 Ironhead Sportster engine in 1975 Harley Sportster hardtailed frame and DNA Springer fork.

Picture of 1981 Harley Ironhead Engine in 1975 Hardtailed Sportster Frame with DNA Big Twin Springer by Lloyd.

Photo of 1981 Ironhead Sportster engine in 1975 Harley Sportster hardtail frame and DNA Springer fork.

Photo of 1981 Harley Ironhead Engine in Hardtailed 1975 Sportster Frame with DNA Big Twin Springer by Lloyd.

Photo of 1981 Ironhead Sportster engine in 1975 Harley Sportster hardtail frame and DNA Springer fork.

After Rebuilding: 1981 Ironhead Custom Bobber

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

Picture of 1981 Harley Ironhead Engine in 1975 Hardtailed Sportster Frame with DNA Big Twin Springer by Lloyd.

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

(January 2010)




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