The following instructions show the installation of a David Bird hardtail frame on a 1979 - 1981 Harley-Davidson Sportster motorcycle frame. David's innovative design is a bolt-on hardtail that does not bolt to the stock shock mounts as others do, giving a much better looking final product. David Bird hardtails and all provided hardware is made in the U.S.A. This hardtail frame in addition to Lowbrow Customs' curated selection of the best Sportster chopper parts will get you down the road in style in no time flat.
NOTE: The stock caliper bracket and caliper cannot be used. You need to use a caliper bracket and caliper from a 1987 - 1999 Sportster.
STEP 1: Start by stripping down the rear of the frame including swingarm. Using a reciprocating saw or cut off wheel, cut where shown in red.
STEP 2: Grind and smooth as shown around seat area so that the upper hardtail tube ends clear.
STEP 3:. The lower lugs can be capped off or cut where shown in red.
STEP 4:. If you have decided to cut the lower lugs. Grind and smooth as shown.
STEP 5: Position the hardtail on the frame and using C-clamp to keep downward pressure and a rubber mallet seat the top of the hardtail tight Against the back bone and as far forward as possible.This is a very tight fit.
STEP 6: Temporarily install the bottom bolts.
STEP 7: Match drill thru the two top holes using a 3/8" drill as shown.
STEP 8: Remove the hardtail and drill the two 3/8" holes out to 5/8" (IN THE TOP WALL ONLY) using a 5/8" drill or a 5/8" step bit drill so sleeves fit inside.
STEP 9: Insert the supplied sleeves into the holes making sure they go all the way down to the bottom of the tube, and grind the front tube to be flush with the back bone and grind the back tube so that it is above the back bone 1/8".
STEP 10: Reinstall the hardtail and hold in place with the two supplied 2 ¼" long bolts, washers, and lock nuts ( Do not tighten yet). Install the supplied lock tabs and bolts into the bottom. 1 ¼ " long in the front and 1 ½ " long in the rear on both sides. All bolts can now be torqued to 25ft. lbs. Using pliers, bend up the lock tabs on all four bottom bolts as shown.
STEP 11: When reinstalling the rear wheel the stock caliper and caliper bracket cannot be used. A Stock H-D caliper and caliper bracket from 1987 to 1999 will be needed.
STEP 12: Wipe that grin off your face, finish up the rest of your bike and go RIDE!