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  #1  
Old 05-04-2008, 06:29 PM
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Default Replica Panhead kits

I am considering buying a replica panhead kit. I have searched the web and found three sites offering complete kits. Tejas Thump Cycles, Roadrat Roberts Custom Products and Chopper Cycle. I was wondering if anyone has built any of these kits and what you thought about them, or if there are any others to consider. I own a 2001 Fat Boy and can do general maintenance and repairs but I have never tried anything like this before. I would really like to build one as opposed to buying a finished one. Any thoughts would be appreciated.

Neil
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  #2  
Old 05-05-2008, 01:45 PM
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I have not built a kit bike like these but if I was to I'd consider buying either a Flathead Power (now S&S) or Accurate Engineering engine and a V-Twin frame as the basis.

Good luck.
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  #3  
Old 05-06-2008, 01:17 AM
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I believe the kits come with 74" S & S engines. The kits are advertised as complete with all parts except paint and fluids. I have never tried a project like this so I thought it would be easier than trying to buy all the parts separately.
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  #4  
Old 05-07-2008, 09:39 PM
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S&S has a new kit for Shovels, 66-84 using P-series heads, hydraulic tappets, Quickee pushrods and forged roller rocker arms. They, S&S, says you can use any cam from S&S's 84-99 cam group. I know this won't work in your bike but if you have a Shovelhead around.
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  #5  
Old 05-08-2008, 01:15 AM
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Thanks for the info. Yeah, your right not gonna work for what I want to do. I was hoping someone on this site had built one of these kits. Maybe someone will see this thread. There is a lot of good info on this site.

Neil
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  #6  
Old 10-13-2008, 11:43 PM
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Default '55-57 Panhead Kits

I'm building one. A V-Twin® replica rigid rolling chassis with an OE motor and transmission.
You can see it over at :: Harley-Davidson Panhead and Flathead site ::, but you have to register to view the section called "Repop".
It keeps spammers and spoilers away.
I've been posting pics of trouble spots and solutions as I put it together - currently installing a set of OEM '51-53 fuel tanks.
Too bad, they don't make replica 3.5 tanks. I would suggest getting a set of real tanks before you invest in a "kit". They are expensive to build ground-up. Knuckle & Panhead kits aren't for everyone. I like building them. At some point you begin to feel like a blend of God and Dr. Frankenstein, and it just keeps getting better as the parts fit together. For sure there is no motorcycle that has quite the same visual impact as a rigid Pan.
•••••••••••••••••••••••••••••
Get some real tanks, a motor from Accurate or Stetts; a V-Twin® 4-spd re-worked trans from either of them - and you can build a rolling rigid frame from V-Twin. Glide forks. I did, with no major power tools. I'm a repair plumber, and building this machine was like one long job. Can't leak when your through. But, fun too. The next one will be easier.


Tank Shut-Off Valve tool. Once the dents are removed with Eastwood's stud welder, this tool will align the upper and lower tank holes. I used it on a CCI left tank half and it works great. You don't need to hammer it at all. You can see the procedure under "Panheads" on the http://hydra-glide.com/ > Forum.
I have reason to believe that V-Twin® is making the new 3.5 gallon tanks. The parts V-Twin® are producing now are as good as any Harley-Davidson® ever made. Forget about the repop from 30 yrs. ago. I can see the V-Twin plan® being implemented all the way through to packaging.
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Last edited by VintageTwin; 10-18-2008 at 12:32 PM.
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  #7  
Old 10-17-2008, 06:37 PM
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I built a real panhead from the ground up. It took me 1 year to complete and was worth every busted knuckle and long hours just trying to find parts.
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  #8  
Old 10-30-2008, 01:09 PM
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Here's a '51-53 tank in need of alignment. Before the dents were removed, the shut-off knob could be turned down only about half-way and it stopped. The blue tape is tape there temporarily, to allow the aligning bar to be turned in slowly, but like a lug wrench. Use WD-40 on the threaded end.
The bar is first used with the thick "alignment" position to tighten against the lower collar (which acts as a spacer-stop. Don't pay attention to the *thru-hole in the spacer.) Wherever direction the bar-end points, will indicate how far off the top of the bar may be, in alignment with the top tank hole. (See pic below).
[* V-Twin though it better to keep the "alignment/spacing" bar intact with the aligning bar by peeing both ends. As OEM, the bar was originally removable, and threaded through the spacing-sleeve holes you see. And probably, a lot of bars got lost back in the day.
The loss of rod height reach into the tank interior (approx 1/4", by not utilizing the thru-holes for the bar), does not affect the visual readability of seeing the end of the alignment bar direction. So here, imo, V-Twin improved on the original design]

I have a min-mag light beam focused on the top of the threaded end of the alignment bar. You can see how much I need to bend the alignment bar at the bottom, in order to (and move the bar to the right) line the hole up.

The crossbar (in alignment position), allows a goodly amount of leverage. You can dial the hole alignment in, until the threaded (pilot)-T can be turned into the alignment bar and bottomed out by hand. Sweet :!:

Then, back the alignment bar off and let the collar move up so you can slide the crossbar to "Spacing". Then turn the alignment bar in again until the collar seats again. Turn the small (pilot)-T inward some more, until it bottoms out again. Now tighten the "Spacing" crossbar tight. Notice that the end of the spacing rod is making even contact with the bottom edge of the collar.
At this point the upper and lower tank holes are lined up.
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Last edited by VintageTwin; 11-13-2008 at 12:24 PM.
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  #9  
Old 11-06-2008, 10:29 AM
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Default Oil Feed Line to (old style) S&S Pump

The early S&S pumps require a street-45 (1/4" male x 1/4" female) into the pump cover and the Harley flare adapter fitting that threads into the female 45.

You have to make up your own 3/8 cad brake line. NAPA® no longer carries the cad brake lines in Calif. which freaked me out and I had to find a new source quick. Carquest® carries it. Get a stick for when you need it. Check out the flare on the brake line. It's a hydraulic flare, not a 37-degree.
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Last edited by VintageTwin; 11-13-2008 at 10:40 AM.
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  #10  
Old 11-12-2008, 11:46 PM
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11-12-08 Actually, you can re-bend a stock-style V-Twin cad. plated feed line to match the pump fitting angle, and still use the original tube flares without cutting the pipe at all. The Ridgid 3/8th tube bender made removing the original bends possible and easy, using the leverage of the long handles. It doesn't look like much, but the flares fit evenly on the nipples and the nuts can be spun up by hand.

It's easier to re-bend a V-Twin rigid frame feed line than it is to create your own out of brake line stock.
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