Every year for the past 14 years I have built a bike over winter, and rode it all summer! I have mainly done Ducatis, one Guzzi, and last year a Honda SLR.

I pondered for a while what to do next, in a way I regretted doing the honda as I missed the grunt of a big V twin... When this Buell came along I jumped at the chance to buy it! It's in excellent condition, apart from a bubbling and swelled plastic tank. The original owner had already modified it, so I decided to do a full rebuild... here is the story so far!



First job has been to address the plastic tank… While it’s not too bad, its already showing signs of bubbling due to the ethanol in the fuel… I hate plastic tanks, so it has to go. Plan was to make an alloy under tank and then make a fiberglass seat and tank cover. However, I had an old Ducati Monster tank that was rotted out on the bottom so I got Arnie the angle grinder out and cut it up… just to see! I was really pleased with the shape and how it fitted! It did of course mean that I would lose that nice Buell filler cap, so instead of using the Ducati one, I made a conversion ring to take the Buell one, it worked a treat.

I made a new bottom for the tank out of some 1.2mm mild steel, and TIG brazed some mounting lugs on, and also a plinth for the fuel tap. This didn’t go well and I got some leaks (good job I pressure tested before putting the bottom in!) The reason was due to my TIG settings… you need both pre AND post gas with braze and you need to flood the weld area with gas before you arc up. The tap plinth brazed on much better. I did mill some shoulders to make it easier as its 10mm thick.

here's some of my previous builds!

nice work Buzzer
looks like you have some previous experience
keep us posted on your progress

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Feros Ferio

there is more already!

As I am using a Ducati tank, the seat didnt line up... so I made a new seat unit...





I pondered for a few days on the final shape... I decided on "C"



https://www.youtube.com/watch?v=2P5jEA18BSI&t=1s

You certainly have some skills
The Ducati gives the appearance of "purpose" (the same IMO as the S1)
Wishing you best of luck with the rest of the build, and I'm looking forward to seeing the end result 👍

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I hate being strapped for cash....but it pays the bills

one thing I have often regretted is not fitting a steering damper… not sure if the bike will need one, but they are difficult to retro fit so I decided to fit one anyway…

This entailed making a lug which I wanted to be a tight fit on the frame…I didn’t have a 30mm cutter, So I used a fly cutter adjusted to size!





I Collected the headlight brackets from the water jet cutter, and make an engine cradle so I can lift the frame off easily. I love going to the water jet place, always an interesting visit! Today they were cutting 100mm titanium plate!



Also made a frame to make engine removal easy!

Great work

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Last year I joined a group for anti-social people
We haven't met yet.

Nice one.

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Ride Safe & Stay between the hedgerows.

well it didn’t take long to get it all apart! Engine out and on the bench… frame welded and off to the shot blasters… I have always had my frames powder coated at a company I have used for years… Last year they let me down badley, lots of broken promises, and in the end I went and collected a frame unfinished. I decided to have it media blasted and do it myself… it worked out well so I have done the same this time. It was back today and its an excellent job.

One of the common problems with the sportster engine is leaking cylinder base gaskets, this one had sighs of a slight leak so for the cost of a set of gaskets I decided to replace them… Pistons are very big! its all like new in there as you would expect for 5000 miles. While I looked a the bike, one thing was bugging me… that straight case line on the engine… so I modified the casing slightly…I like it… many wont!

The seat is back from the trimmer, and as usual it’s a superb job! The weather has turned cold which meant I had to resort to drying the smaller painted parts in the oven… Good job she is OK with it these day, although the line had been drawn on the dishwasher!

I debated on taking the parts in to the platers, they did a great job last time BUT they did lose a few items, luckily nothing of importance. Not wanting that to happen this time I decided to do it myself again and got out my plating kit which I have been using for years… still great results! They say the devil is in the detail, I see so many builds spoiled due to dull and rusty plated items…

Going together nicely… I do need to slow down! However I made a big fxxxup the other day when I took the rear shocker apart… I forgot they work opposite to normal so when I undid the adjuster nut, I was actually applying more tension onto the. it came off the threads and I realised I would never be able to get it back on… rookie error. I had to cut the outer shroud off. I hope to rescue it as a new one is mega expensive… will post pictures in a few days! but for now here it is going together.

This build looking good Buzzer

If you decide to ever buy another shock for the buell you better invest in a aftermarket one instead a original!

Which length of shock do you have?
And I don't know if it's helpful for you , but I have a original type shock in used condition that is the long version.
Don't know how good or bad the condition is because it came with some other spare parts along a S1 some years ago and so I never tested it.
But if you think you can make something from it for your motorcycle you can have it for only the shipping costs.
But I'm living in Holland ,so there's probably also extra import tax to the UK.
But if you want I can have a look into the shipping costs.
You also can send me a pm with your email address and I will make a couple pictures from the shock.

Have a good weekend
Cheers
Mees

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The sound of a V-twin engine braking is music to my ears!!

thanks for your kind offer Mees

Well I pondered about the shocker… The reason I took it apart was I wanted to expose the spring, but it just didn’t trigger that it works the exact opposite to normal! I looked around and liked the design of the Ohlins one and decided to copy the idea. Back to the water jet cutter to have some plates cut, and I turned them down in the lathe. I drained the oil out and put some in a small bottle with a funnel type top… I timmed how long it took to drain out… then tried some 10 grade oil… much slower… then tried 5 grade and it was the same time! Looks like its SAE 5 in there! Soon as it's on the road I will take it and get it nitrogen filled… but for now I have put some air in there.