The following instructions show the installation of a David Bird hardtail on a 1954 - 1972 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. We also installed 1982-2003 Sporster David Bird hardtail on another project by our experienced fabicator, which makes you interest.
STEP 1: Start by stripping down the rear of the frame including swing arm.
STEP 2: The 1954 - 1972 Sportster frames have a 'forged style' seat post bracket area, including the shock mounts. This needs to be cut away as shown below using an air or electric grinder with cut off wheels, sawzall, or whatever you find most convenient. Flap discs or a die grinder with sandpaper discs make quick work of smoothing and blending your frame after cutting.
STEP 3:. Grind the top of the seat post rails to approximately 165 degrees or so, so that the plate on the top of the hardtail sits flush when held in position.
STEP 4:. Position the hardtail on the frame and using a rubber mallet seat the top of the hardtail tight against the down tube and clamp as shown below.
STEP 5: Drill thru the existing two top holes into the frame rail below using a 3/8" drill bit.
STEP 6: Remove the hardtail and drill the two 3/8" holes out to 5/8" (IN THE TOP WALL OF FRAME TUBING ONLY)
STEP 7: Insert the supplied sleeves into the holes making sure they go all the way down to the bottom of the tube as shown and grind the top to be flush with the down tube.
STEP 8: Reinstall the hardtail and hold in place with the two supplied 2-1/4" long bolts, washers, and nylock nuts (do not tighten yet). Install the supplied lock tabs and bolts into the bottom, 1-1/4" long in the front and 1-1/2" long in the rear on both sides as shown below.
STEP 9: All bolts can now be torqued to 25 ft. lbs., then, using pliers bend up the lock tabs on all four bottom bolts as shown.
STEP 10: Wipe that grin off your face, finish up the rest of your bike and go RIDE!