Welcome
to the JH Choppers 2006 FXSTI EFI Chopper Project Page.
With the Paint Process complete, its time to build a chopper. Install the motor, wheels,
transmission, ... stretch the Wire Harness...
With the Paint Process complete, its time to build a chopper. Install the motor, wheels,
transmission, ... stretch the Wire Harness...
| The
New Black Frame: The
frame is prepped after powder coating, all the threads must be chased out with
a tap. Then the swing arm and frame are assembled with the rear wheel mounted
in the wheel vice. Mad Matt stopped by to lend us a hand with assembly process. | ||||
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| Install
the Front End: The
triple trees are installed with the new pull back drag bars. Then the 12 over
front forks and the new wheel with matching brake rotor. The engine and transmission
are placed, its starting to look like a new chopper now... | ||||
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| Motor
Details: The
stock 2006 Engine and Transmission have the sandblasted and clear look from Harley-Davidson.
This industrial look was accented by removing all chrome parts from the motor
and replacing them with brushed 6061. The rocker boxes were removed and brushed
for a cool industrial looking power plant. A custom points cover was made, first
sandblasted, machined, then clear coated. | ||||
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| Primary
Drive: The
inner primary, clutch basket and compensation sprocket are installed. Starter,
jack shaft, oil tank, and outer primary are then installed. The stock finish is
then complimented with a custom inspection and durby covers. These cover were
sandblasted, machined and clear coated to match the OEM finish. | ||||
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| Air
Ride: The
air ride has on board air compresser, this is installed under the transmission,
hidden from view. The air line are connected to the shocks and tested with a battery.
Some of the other electrical components are installed. | ||||
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| Custom
Ignition Switch Housing Mount (Part 3):
The stock ignition switch was replaced as the stock tank
and dash are now gone. The 6061 insert was now CNC Machined to hold the new switch,
all the wires are run internally for a clean install. After sanding and pollishing,
the switch looks great! | ||||
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| Cables,
Front Fender, and Controls: The front
fender is installed with new custom fender spacers. The controls are installed
so the new clutch cable, brake line, idle and throttle cables can be measured
and installed. The tank is placed on the back bone so the final wiring placement
can be done. The upper wire harness needs to be stretched so the wires can be
hidden under the tank. | ||||
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| Wires
and Wires: For a clean look, the stock
wire harness is cut and stretched for each sensor, injector and connector on the
bike. This allows the wires to be hidden under the tank, seat and in the handle
bars and is necessary with the frame stretch. Each wire assembly is cut and wrapped
with a nylon protective coating for both functionality and a clean look. | ||||
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| EFI for Chopper Tanks (Part 3): With the old EFI parts removed from the stock tank and installed into the Roland Sands "Gas It" kit, its time to install it into our new Chopper Tank. Masking tape is used to protect the new paint during the install, all the hardware is lubricated with loc-tight. The Stock Fuel line will be replaced with a new longer high pressure EFI line and fittings For more information on this kit, check out www.RolandSand.com | ||||
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Back to the Paint Process (PREV) | ||||
