Rear Hot Mockup - Make sure all the parts
fit, make custom parts and adjustments as
Swing Arm: Once we have the bearings pressed
into the new swing arm. Attach it to the frame,
don't forget the belt. Check the clearance
at both the top and bottom. Make sure the
swing arm can move up and down freely. Grind
Air Shocks: Install the new shocks from Legend-Air.
We had clearance problems with the new swing
arm, it lowered the rear shock mount about
1/4 in. This is OK, if your installing stock
shocks. But the shafts on the Legend-Air are
larger than stock, thus we hit the transmission
Swing Arm Modification: After the shocks
were installed, we noted that the swing arm
travel was limited and the shocks we not parallel
to the bottom frame rail. To increase the
travel and improve the appearance, we need
to remove about 1/2 in of the swing to shock
mount and reattach it. Mitch Hamilton was
in for the weekend and was ready to lend a
Swing Arm Weld: Here is the final weld after
it has been installed.
Transmission Mount: The transmission will
be mounted 1 1/2 in off center, so the mounts
will need to be moved. A new mounting plate
takes care of 4 main bolts( with a small modification
). But a special bracket will be needed for
the 5th mount.
The new transmission mount has a 1 in offset,
so we cut mount and weld it back with a the
target 1 1/2 offset.
Primary Drive: The primary drive is installed
before the 5th mount is welded to the frame.
A 1 1/2 in spacer is installed before the
primary drive is bolted to the engine.
This insures proper alignment of transmission
with the new 1 1/2 in offset.
Transmission Mount: The transmission is then
installed and connected to the engine with
the primary drive before we weld one the new
5th mount. This will insure proper alignment.
A tack weld is applied to the extension plate
(this is the plate that we cut above)
The 5th mount is now welded to the frame
with transmission bolted to the primary cover
Rear Wheel Preparation: Before we install
the rear wheel, we cover all the polished
edges with duct tape to prevent scratches.
The rear pulley and break rotor is installed
To save a much room as we could, the left
rear hub was machined 4mm were the pulley
bolts onto. This places the belt as close
to the wheel as possible. The right hub was
machined 5mm on the break side. The caliper
mount was also milled 3mm.
Rear Wheel Mount: We mounted the rear wheel
and centered it with the frame. With the wheel
centered, 4mm inset on the pulley and 8mm
additional offset on the transmission, the
wheel pulley and transmission pulley should
line up. We used masking tape and angle iron
for centering up the wheel.
The swing arm frame mount will need to be
removed and extended 10mm for the belt to
clear the stock frame.
Frame Modification: Remove the wheel and
swing arm for the 10mm offset. Cut off the
swing arm frame mount.
After a tack weld was applied, the swing
and wheel were remounted to check the alignment.
Here is the finished bracket.
Frame Modification: Before we can mount the
rear fender and for wheel clearance, we need
to remove the stock fender struts.
Rear Brake Installation: With the drive side
aligned, mount the rear wheel with the caliper
bracket. Earlier, we had 5 mm removed from
the brake side wheel hub and 3mm from the
Rear Fender Installation: A Wernimont rear
fender was mounted using the old fender struts
holes and connected under the seat new pan.
Using cardboard as a template, sheet metal
plates were cut and welded to the fender.
Ribbing was added just below the seat for
Rear Fender Customization: We laid out a
pattern on the back end of the fender with
masking tape, after trying a couple different
patterns, we cut the 'tail' out. Using masking
tape on the tire, we made sure the tail remained
in the center.
Seat Pan Installation: The seat pan was modified
for a custom fit onto the new super wide fender.
The seat cover and foam pad were removed and
the pan was cut and welded to fit. We were
able to push the seat backwards about 1.5in
and lowered an additional 1in. Some pop-rivits
were used to place the seat cover back on.
A custom seat logo was also added (thanks
Rear Fender Customization: To complete the
rear fender, additional sheet metal was added
to each side near the swing arm for a clean
line with the frame. Then tubing was added
to the tail for additional support and to
complete the final look.
Completion of Rear Hot Mockup Phase: After
several months, the rear hot mockup phase
is now completed. The swing arm, wheel, tire,
drive system, brakes, fender and seat have
all been custom fit to our chopper. There
is still some final body work needed on the
fender and swing arm, this will be completed
during the paint preparation phase.
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