Boot side panels
Next boot related project are the side panels. These I'm making out of aluminium, line with carpet and some rubber trim to seal them against the tub. Passenger side panel...
Harness Holes Be Gone
I made some blanking plates to cover holes no longer needed in the tub. These are aluminium, painted black then lined with rubber and held on with rivnuts, cup washers...
New front wing stays
The front wing stays rusted and broke again, did a temporary fix a few months ago, but finally it's time to make some new ones which will hopefully be more...
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...
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...
Carbon
Did a little bit of work on the car today, made some carbon fibre scuttle covers. They still need sticking down with the some tape, but they look nice:
Side screens
Side screen are mounted to aluminium brackets via a threaded hole and cut screw. Aluminium brackets cut & drilled. Many, many hours of polishing later brackets ready for mounting. All...
Paint!
It's been a long time coming, but we finally got the Sportster painted and reassembled and here's the result:
Getting there
I was hoping that the car would get finished today, but as always there were more and more little things to do! The centre console now has bracketing to hold...
Centre console, and rear end
The centre console coming together, this will also act as a duct for heater down to your feet. There's also a 12V supply in the side of it for the...
Interior and rear lights
Dash board re-trim without glove box (wiper motor in the way) Rear of re-trimmed dash showing pod for speaker Divers side behind the dash Test fit on car, the mount...
Body panels
All the body panels are off and ready for paint!
Loured Up
After not having much success with the bead roller I went to go see http://www.coollouvres.com/ today, here are the results, I'm really happy with these:
Bodywork final stages of prep for paint
Rough fill in of the holes in the tub with 8 layers of glass to give it plenty of strength. Tub hole cover from the back New side repeaters fitted...
Bodywork update
A few more things checked off the list: Finished the scuttle side panels Opened up the indicator holes on the scuttle to fit the new ones Rear end break down...
Scuttle side panels
New scuttle side panel without louvres compared to the original with louvres. The new one also now has folded back edges which gives a much better edge. New scuttle side...