GreaseRag Web Site Harley Magazine Forums home Page Harley Magazine Subscription Services Harley Magazine Home Page This Month's Issue of our Harley Magazine Harley Magzine Forum Member Photo Albums Harley Magazine Forum Classified Ads Harley Magazine Forum Archives Harley Magazine Forum Event Listings Harley Magazine Forum Links Contact Harley Magaziner Forum American Iron Home Page American Iron Advertising Harley Forum Terms of Service Harley Magazine Subscription Service


Go Back   Harley Forum - American Iron Magazine Harley Forum > Motorcycles > Harley Bagger

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 01-05-2010, 03:22 AM
Todd8080
Guest
 
Posts: n/a
Default Another example of "unitized detachables"

After putting a lot of effort into designing & painting the graphics on my friend Eric's Road King Classic, I always hated the way the detachable luggage rack docking "elbows" stuck out past the rear fender, ruining the lines of the stripes. I told him if it was me I'd do away with the rack altogether rather than have to look at those things sticking out.

But of course I understood the need for a luggage rack, so I suggested an alternative. Why not mount the rack directly to the detachable passenger backrest, that way the rack would still be removable yet leave no ugly mounting brackets behind. He agreed, since the backrest and luggage rack were always either on or off at the same time anyway and said "go for it," so here's what I came up with.

It's really so simple anyone could do it. With the backrest in place and the rack installed on its original brackets, I measured the distance and relationship between the backrest & rack and made two steel brackets out of 1/8" x 1-1/4" flat stock, then drilled four holes in each. Using them as templates I then drilled corresponding holes in the backrest & rack sideplates.

I cut the bottoms off the rack's sideplates (flush with the new brackets) since they aren't needed anymore, but it would still work if they were left on.

I assembled the rig with 1/4-20 polished stainless screws and matching stainless acorn nuts and test-fitted it. Fitment was perfect so I disassembled it and sent the two pieces to the chromer. They came back today, so here are some photos in case anyone would like to do something similar on their bike.

The first two pictures are how it looked before with the "elbows" installed; the last three are the finished product with the "elbows" removed and the backrest & integral rack installed.

http://i472.photobucket.com/albums/r...-Lights-16.jpg
http://i472.photobucket.com/albums/r...-Lights-17.jpg
http://i472.photobucket.com/albums/r.../EricRack1.jpg
http://i472.photobucket.com/albums/r.../EricRack2.jpg
http://i472.photobucket.com/albums/r.../EricRack3.jpg
Reply With Quote
  #2  
Old 01-20-2010, 12:46 PM
Todd8080
Guest
 
Posts: n/a
Default Re: Another example of "unitized detachables"

In case anyone's curious about the term "unitized detachables", it simply means combining two or more components and making them detachable as a single unit. Here's another example of that on my own bike, a custom FL Softail.

I like the option of having a removable windshield, but when it's on there's a strong updraft coming up between the windshield and gas tank, particularly annoying if you have facial hair. The solution for that is fork-mounted lower wind deflectors.

But when the windshield's off, the wind deflectors alone look ridiculous. The natural cure for that was to make the deflectors part of the windshield, so they come off when it does.

Not being satisfied with Harley's steel deflectors, I designed my own out of Lexan, which are slightly larger yet less noticable, and meet the windshield neatly for less of a gap for wind to get through.

In the "old days" Harleys with passing lamps didn't have that unsightly bar underneath the headlight that connects the passing lamps to each other, they were attached to separate brackets mounted on either side of the fork. But in addition to wanting to lose that bar, I also wanted to get rid of the turn signals under the passing lamps (also the "old style"), yet I still wanted working turn signals. The solution was to put the turn signals inside the passing lamps.

Of course it was important to make all these components look like they were intended to be a unit, not just stuck together haphazardly, so I designed brackets that hold the passing lamps and wind deflectors. They're made in such a way that from the side it looks like the passing lamps are floating in space, unattached to anything.

Naturally I didn't want the factory look of two large wiring bundles coming from the passing lamps, so I used one multipin plug to power the lamps. Its single wire bundle plugs in to a receptacle under the lower triple tree next to the left fork leg. The right passing lamp/turn signal's wires run from the left passing lamp along the bottom edge of the windshield and over the headlight and are concealed by chrome edge trim. When the windshield's on the bike you really have to look hard to see the wires.

Here are the two brackets that hold the passing lamps and wind deflectors, before being chromed:

http://i472.photobucket.com/albums/r...ctorBrkts3.jpg

And a closeup of just the left bracket, showing the passing lamp mounting tab & its wire routing hole:

http://i472.photobucket.com/albums/r...ctorBrkts4.jpg

Here's the complete windshield/passing lamp/turn signal/wind deflector unit off the bike:

http://i472.photobucket.com/albums/r...ctorBrkts6.jpg
http://i472.photobucket.com/albums/r...ctorBrkts5.jpg

And here are some closeups of it on the bike:

http://i472.photobucket.com/albums/r...ctorBrkts9.jpg
http://i472.photobucket.com/albums/r...torBrkts11.jpg
http://i472.photobucket.com/albums/r...torBrkts12.jpg
http://i472.photobucket.com/albums/r...torBrkts13.jpg
http://i472.photobucket.com/albums/r...torBrkts15.jpg
http://i472.photobucket.com/albums/r...torBrkts19.jpg

Perhaps you're wondering how visible the turn signals are when the passing lamps are on, since they share the same housings. I took that into consideration when designing the wiring system. Using a relay inside each passing lamp, I wired the signals so that when they're activated they each momentarily kill their respective passing lamp when lit, so all you see on that side is the amber turn signal. I figured that even if cars didn't see the turn signal, it would be hard to miss an alternately flashing 35-watt halogen passing lamp.

Passing lamps off, left signal activated:

http://i472.photobucket.com/albums/r...torBrkts21.jpg

Passing lamps on, left signal activated:

http://i472.photobucket.com/albums/r...torBrkts22.jpg
Reply With Quote
  #3  
Old 01-20-2010, 01:13 PM
Gas Man's Avatar
Senior Member
 
Join Date: Jun 2009
Location: Metro Detoilet
Posts: 919
Default Re: Another example of "unitized detachables"

I love what you've done with the passing lamps. A++
__________________
^^My $0.02 not yours^^

-Chris
aka Gas Man

"Why pay someone else to f**k up your bike?"
Reply With Quote
  #4  
Old 01-20-2010, 05:51 PM
hardtimeharley's Avatar
Senior Member
 
Join Date: May 2009
Location: middle georgia
Posts: 207
Default Re: Another example of "unitized detachables"

Nice set-up. But no turn signals when the windshield is off?
__________________

'68 ?? Rigid "Shovelstein"
'92 FXDC
'07 FLHTC
Reply With Quote
  #5  
Old 01-20-2010, 07:00 PM
Todd8080
Guest
 
Posts: n/a
Default Re: Another example of "unitized detachables"

Thanks, Gas Man.

Hardtimeharley, I made mini plug-in LED signals for when the windshield's off, but I usually don't bother to put them on.

Here's another example of "unitized detachables", the Shovelhead saddlebags on my bike. I considered using late-style dresser bags but have never liked the sharp-edged "squareness" of them or the shock indentations, not to mention the raised bracket channel at the bottom, so I found a set of '77 bags on eBay for $60, in pretty rough condition I admit, and set about modifying them to fit my Softail (warning: these are all crappy, lo-res photos).

http://i472.photobucket.com/albums/r...ags/Bags01.jpg

One thing that was important to me was that they look clean, that is, without the usual external hardware found on stock '77 bags. So I designed hidden latches, locks and hinges that were completely internal. This also solved the age-old problem of Shovelhead bag lids flying off unexpectedly on the road. Even if I forget to latch them they can't come loose.

http://i472.photobucket.com/albums/r...ags/Bags02.jpg
http://i472.photobucket.com/albums/r...ags/Bags03.jpg
http://i472.photobucket.com/albums/r...ags/Bags04.jpg
http://i472.photobucket.com/albums/r...ags/Bags05.jpg
http://i472.photobucket.com/albums/r...ags/Bags06.jpg
http://i472.photobucket.com/albums/r...ags/Bags07.jpg
http://i472.photobucket.com/albums/r...ags/Bags08.jpg
http://i472.photobucket.com/albums/r...ags/Bags09.jpg
http://i472.photobucket.com/albums/r...ags/Bags10.jpg

I also designed detachable support brackets that were part of the bags themselves, rather than using the stock Shovelhead "racks" that bolted to the struts. That way the bags could simply be lifted off leaving nothing behind. Since I already had Harley docking hardware installed for the detachable passenger backrest, I decided to keep those as the saddlebag docking hardware and adapt my design to use them. To avoid using a support "bridge" under the rear fender, I added a docking grommet to each muffler support to make them also the bottom bag supports. I later added additional docking grommets to the bags' upper brackets for a separate detachable backrest, meaning I can use either separately or both together.

http://i472.photobucket.com/albums/r...ags/Bags11.jpg
http://i472.photobucket.com/albums/r...ags/Bags12.jpg
http://i472.photobucket.com/albums/r...ags/Bags13.jpg
http://i472.photobucket.com/albums/r...ags/Bags14.jpg
http://i472.photobucket.com/albums/r...ags/Bags15.jpg
http://i472.photobucket.com/albums/r...gs/Bags15a.jpg
http://i472.photobucket.com/albums/r...ags/Bags16.jpg

Something else I never liked about late Harleys is the rear turn signal bar, so I incorporated the running lights and turn signals into the saddlebags. For the lamp bodies I used inexpensive CCI marker lights cut in half (to reduce their size), and designed my own LED arrays for them that use red LEDs for running lights and amber LEDs for turn signals, all in the same housing. While I was at it, I installed white LED interior lights in the lids to make night loading easier.

http://i472.photobucket.com/albums/r...ags/Bags17.jpg
http://i472.photobucket.com/albums/r...ags/Bags18.jpg
http://i472.photobucket.com/albums/r...ags/Bags19.jpg

To get power to all the lights, yet leave no exposed electrical connectors when the bags were off, I installed multipin connectors on the underside of each strut. They're completely invisible unless you happen to be laying on the ground looking up.

http://i472.photobucket.com/albums/r...ags/Bags20.jpg

Because the bags are on a Softail, there are no shocks in front of the bags (as there are on a Shovelhead), which leaves somewhat of a "hole" in that area. The obvious solution was to fill that space with Softail rear crash bars (or "saddlebag guards"). But this presented another problem, since the bike would look very odd when the bags were off, leaving just the rear crash bars sticking out like Dumbo's ears.

So I reversed the crash bars, mounting the left one on the right side and vice versa, and instead of bolting them to the frame I mounted them to the bags themselves.

http://i472.photobucket.com/albums/r...ags/Bags21.jpg
http://i472.photobucket.com/albums/r...ags/Bags22.jpg

Then of course there was plenty of filling, sanding and priming to do before paint:

http://i472.photobucket.com/albums/r...ags/Bags23.jpg
http://i472.photobucket.com/albums/r...ags/Bags24.jpg
http://i472.photobucket.com/albums/r...ags/Bags25.jpg
http://i472.photobucket.com/albums/r...ags/Bags26.jpg
http://i472.photobucket.com/albums/r...ags/Bags27.jpg

This is the finished product:

http://i472.photobucket.com/albums/r...ags/Bags29.jpg
http://i472.photobucket.com/albums/r...ags/Bags30.jpg
http://i472.photobucket.com/albums/r...ags/Bags31.jpg
http://i472.photobucket.com/albums/r...ags/Bags32.jpg
http://i472.photobucket.com/albums/r...ags/Bags33.jpg

And in seconds it all lifts right off to leave a stripped-down boulevard cruiser:

http://i472.photobucket.com/albums/r...ags/Bags34.jpg
http://i472.photobucket.com/albums/r...ags/Bags35.jpg
http://i472.photobucket.com/albums/r...ags/Bags36.jpg
http://i472.photobucket.com/albums/r...ags/Bags37.jpg
Reply With Quote
  #6  
Old 01-21-2010, 08:35 PM
usturbine's Avatar
Member
 
Join Date: Mar 2009
Posts: 32
Default Re: Another example of "unitized detachables"

Very nice work. The bike also looks great with the shovel style bags.
__________________
made it another year 7 years cancer free everyday is a good day some are just better than others
Reply With Quote
  #7  
Old 01-23-2010, 08:44 PM
Todd8080
Guest
 
Posts: n/a
Default Re: Another example of "unitized detachables"

Thanks, Usturbine.

Slight update on the Road King Classic: In my haste I neglected to take any photos of the bike showing how it looks with no rack, backrest or docking "elbows". Eric stopped by today so I took a couple of shots:

http://i472.photobucket.com/albums/r...-Lights-18.jpg
http://i472.photobucket.com/albums/r...-Lights-19.jpg
http://i472.photobucket.com/albums/r...-Lights-20.jpg

And if anyone's curious about the lights in the saddlebags, here's the story on that:

My pal Eric was due for new saddlebags for his '98 Road King Classic, and I talked him into getting Road King Custom bags, which don't have the straps & buckles but instead have a hidden latch for a cleaner look. He found a nice set on eBay for about half of Harley's cost.

He asked me if I'd make a set of LED lights to mount in them, since we did away with the rear turn signal bar several years ago. He wanted ones similar to mine, with yellow LEDs for signals and red LEDs for running lights.

But he also wanted me to incorporate a third circuit for red brake lights, so that's what I did and here are the photos, just in case you'd like to try something similar yourself.

I started by making these little wedge-shaped boxes out of 16 gauge sheet steel to use as housings. They're shaped like that because LEDs are directional and need to shine horizontally, but the backs of the bags are slanted at an angle.

http://i472.photobucket.com/albums/r...-Lights-02.jpg

The one on the left is positioned pretty much as it will sit in the bag. The little tabs on the sides are 10-32 nuts I welded on for attaching them.

http://i472.photobucket.com/albums/r...-Lights-03.jpg

Here you see one of the circuit boards I made up just set into place. The lights run vertically and alternate red then yellow to spread out the light. I painted the both boxes with spray-on truck bed liner, the same stuff I used on my in-the-fender tool box. The bottoms are open to allow some light into the bags for loading/unloading.

http://i472.photobucket.com/albums/r...-Lights-04.jpg

To further dissipate the light I added a layer of refracting plastic, the stuff you see in kitchen drop ceilings. The screws here are just temporarily to hold the light in place; the finished light will have black countersunk stainless screws.

http://i472.photobucket.com/albums/r...-Lights-05.jpg

Next come the lenses. I got a 12"x12" piece of smoked 3/16" acrylic sheet at a local plastics supplier for $4, enough to make two sets of lenses (such a deal). I chose smoked because it helps hide the housings and creates the illusion of no lights when they're unlit.

http://i472.photobucket.com/albums/r...-Lights-06.jpg

Here are the lenses cut out, with the edges beveled and polished to a high gloss. The protective paper stays on until it's time to mount them.

http://i472.photobucket.com/albums/r...-Lights-07.jpg

And here's everything installed. You can just make out the refracting layer behind the smoked acrylic, but I didn't want to go any darker because the darker you go, the less light escapes. The wires run under the bags and plug into receptacles just behind the bike's sidecovers.

http://i472.photobucket.com/albums/r...-Lights-11.jpg

Please excuse these next shots, they're blurry because the camera was hand-held in a low light situation with no flash. This one shows just the running lights (a single verticle row of seven red LEDs).

http://i472.photobucket.com/albums/r...-Lights-12.jpg

This photo shows the running lights plus the brake lights, which are four vertical rows of six red LEDs.

http://i472.photobucket.com/albums/r...-Lights-13.jpg

The last shot shows the running lights and both turn signals. The yellow LEDs pretty much drown out the running lights, which is good.

http://i472.photobucket.com/albums/r...-Lights-14.jpg
Reply With Quote
  #8  
Old 02-08-2010, 09:52 PM
Member
 
Join Date: Jan 2010
Posts: 26
Default Re: Another example of "unitized detachables"

THis '09 Ultra with a detachable tour-pak belong to a guy on one of the other H-D Forums.
Attached Images
File Type: jpg 2009 UC (2).jpg (61.2 KB, 9 views)
__________________
2009 FLHTCU

Red Hot Sunglow/Smokey Gold
Reply With Quote
  #9  
Old 02-14-2010, 02:25 PM
Member
 
Join Date: Nov 2008
Location: Sun Prairie, Wisconsin
Posts: 12
Default Re: Another example of "unitized detachables"

Nice work Todd. Another way you could further clean up Eric's rear fender would be to hang the license below the fender between the pipes. You've got some real talent. Where are you located?
__________________
Warren ''Bikerdaddy'' Brown
Sun Prairaie, Wisconsin
07 Road Glide
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
"Thunder in the Smokies" or "Cherokee Survivors" Rally? high_beam Motorcycle Events & Travel 1 01-31-2010 02:25 PM
Welcome to "Bikie" Generation "RUB" admin General Motorcycle 17 12-04-2009 03:03 PM
January issue Chris' "lane sharing" article jmk713 General Motorcycle 20 11-28-2009 12:58 PM
South Park takes on the "Loud Pipe Issue." Shooter Bob General Motorcycle 8 11-08-2009 10:27 PM
July '06 Issue - Hot XL "Jeff Blair's Custom Buell" - Parts. admin American Iron Magazine 0 05-21-2007 03:10 PM

» Banners




Powered by vBadvanced CMPS v3.2.1


All times are GMT -4. The time now is 10:34 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2010, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.2.0
(C) Copyright 2007-20010 TAM Communications, Inc.
Google Analytics Alternative