Welcome
to the JH Choppers 2006 FXSTI EFI Chopper Project Page.
With the frame stretch complete, we need to add the rest of the components. Mount the front fender, gas tank with EFI modifications, upper motor mount, and ignition switch housing.
With the frame stretch complete, we need to add the rest of the components. Mount the front fender, gas tank with EFI modifications, upper motor mount, and ignition switch housing.
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Mount the front
fender: The
fender is place onto the front wheel with a drive belt to help set the spacing.
Holes are marked and drilled into the sheet metal fender. Then custom 1 inch JH Choppers Fender Spacers will be used hold the fender in place. | ||||
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| Custom
Fork Brace: With
12 over fork tubes, a fork brace will be needed to support the front end. A custom
JH Choppers Fork Brace will be used. | ||||
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| Engine
Mount: The
TwinCam is place back into the "new" chopped frame to set the motor
mount. The mount is fabricated with a bolt welded into the structure, then it
is spot welded onto the frame. | ||||
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| EFI
for Chopper Tanks (Part 1):
The old EFI parts are removed from the stock tank and installed
into the Roland Sands "Gas It" kit. This allows use to keep the EFI
System on our custom build. For more information on this kit, check out
www.RolandSand.com | ||||
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| EFI
for Chopper Tanks (Part 2):
To install the "Gas It" Kit, a large hole must
be cut into the bottom on the tank where the mounting flange is welded into place.
The hole is marked, then cut out and the flange is welded in. The "Gas It"
kit is placed in to check the fit. Finally, the the crossover holes and peck-cock
holes are removed along with the remaining upper tank mount. | ||||
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Chopper Tank Mount:
The tank is placed on the frame with spacing for the wiring
harness considered. The rear mount is spot welded in place, then welded up. Since
the front mounts were removed for the EFI Kit, new mounts were fabricated and
welded onto the front of the tank and frame. The upper tunnel hole is filled in
for a tighter look. | ||||
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Custom Ignition Switch Housing Mount (Part 1):
The Ignition Switch will be mounted under the tank. Using
some round tubing and chunk of 6061, a housing assembly was fabricated on the
lathe. The inside of the tube was board true and the 6061 cover plate was cut
on the band saw, then turned for a tight match. | ||||
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Custom Ignition Switch Housing Mount (Part 2):
The Upper Engine Mount is cut with a Miller Plasma Cutter.
The Ignition Tube is then notched to match the hole and is welded on the inside
to the Engine Mount, this allows the switch wires to be hidden. A small hole will
be CNC milled for the switch to mount to the new 6061 Plate. | ||||
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Back to the Frame Modification
(PREV) | ||||
