2019 MOT – handbrake failure and fix
So the MOT tester is a beast of a man and ripped both handbrake cables clean off the mounts! Better it failed here than in an emergancy though. The orginal...
Water leek, from back of the head
Another week, another new fluid all over the floor! Coolant this time from the rear port on the cylinder head. That's the pipe that goes to the interior heater core:...
Fuel pipe refresh, car pee’d all over the floor!
Car pee'd on the floor... It's a bit drippy here at the back, but also at the front on to the start motor - not overly safe and smelled pretty...
Coolant flush and refresh
This drain plug has been leaking forever, the drain part is reverse thread and normal thread into the radiator. The thread into the radiator needed more PTFE. Due to topping...
Front indicator stalks refresh
The front indicators were starting to rot pretty badly, replacements are not very expensive so I decided to change them for new. The new ones are little bit shorter than...
Seat Repair
The Cobra Roadster 7 look nice, but the construction quality is questionable at best. After 6500 miles the driver seat broke in two. I'm very happy the nice SVA man...
Upper wishbone refresh and wishbone mounting rod
I changed the upper bushes today. They were rally design ones, which I've now replaced with Powerflex. I thought the bushes had worn as things didn't look straight anymore. Turns...
Reassembly, paint, lighting, electrics
The rear wings, tub and spare cover are back from http://www.specialisedpaintwork.com/ for some touch up work and removal of all the stone chips on the wings! The wings were starting...
3 point reel seat belt conversion
ziptie test, safety 3rd! Hole cut for threaded belt insert Test fit of new piece Use the lathe to clean up these spacers Reel mount Reel mout welded in Upper...
Rear rust clear up
Doing some clean up work, the Sportster has been on the road for a while now so it was time to check for rust and clear anything up Little bit...
3D Printed light bracket finalised and dust cover for LED centre lights
Part evolution from initial concept to final co-polyester print, shown at the front the traditional bulb clear lens, LED amber indicator and LED ring light. The final part: Test fit...
3D Printed light brackets Version 2 test
Version 2 on the left, much smaller than the inital version: Some clearance to fit two next to each other on the Sporster The part is still more than strong...
3D Printed light brackets Version 2 model
Version 2 model, more compact, less print time and should have a good 1-2mm gap to place both lights next to each other. Version 2 Version 1 Version 2 Version...
3D Printed light brackets Version 1 test fit
Test print Version 1 in PLA, some Dremel work needed due to minor measurements being out, mostly it’s Ok!
Light cluster brackets 3D print
Test print in PLA, will be able to test fit in a day or two. The final version will be printed in a copolyester for more heat resilience.
Hella Mix and Match 3D Print Light Brackets
When we first build the Sportster 3D printing wasn't a thing for home users. This has changed in the last 13 years, so it seem like a good time to...