Installed a 3rd level brake light 9 years back as a 'temporary' solution to make it clearer when I was using the brakes. I've been meaning to install something cleaner...
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...
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...
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...
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...
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...
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...
Test print Version 1 in PLA, some Dremel work needed due to minor measurements being out, mostly it’s Ok!
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.
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...
A very temporary solution to make it more obvious I'm using the brakes. Not pretty but does the job until I find a better solution.
It was time for an upgrade after spending a year on and off cleaning contacts and still having the number plate lights blink sometime. Using the original housings the standard...
I took some video with my phone so its pretty cruddy quality but shows the wiper motion:
After spending a lot of time eyeing up the location for the wipers I came to the conclusion that 90 degrees would work best for us. After looking inside the...
To fit the windscreen you'll need some masking tape a pencil, rule and maybe a tape measure! Put some tape down and mark a centre line on the scuttle -...
Some more small things today: Indicators bolted down, they need moving back bit to avoid hitting the front wings on full lock Interior some more zip ties on the wiring...
More small jobs sorted today while waiting for an SVA date: Indicators installed so that they comply with SVA regs: Installed new horns as the ones from the donor died:...
After creating a template for bracket for holding the rear lights 4 more were made as the final products: Each pod needed to be individually tuned to fit the shape...
All the lights are now working! Blew the 7.5amp fuses though. The current on the high beams + spots peaks at 11amps (possible spikes higher) so 15amp fuses are going...
Front bumper installation - just like the back the front does not fit so we made some spacers. Spacer installed, with the spacer in the bumpers fit very snugly! Headlights,...
After nearly a whole measuring the bonnet catches are now install. They really finish the car of nicely. Spent a few hours day creating a centre console out of the...