Harley Sportster "Cam Cover Cut Down" !
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- čas přidán 24. 03. 2022
- A popular modification, easy enough with a little patience !
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Allen Millyard would have done that with a hacksaw. Then he would have made the engine into a V4 :)
My very first job as an apprentice was to draw file and polish some aluminum brackets for a plastic bag making machine. There was 6 of the brackets with lots of flats and radii. It took me a week !
Whilst taking a break to sample Tracy's baking and check on the hedgehogs!
@@Gorbyrev Allen does his baking on the barbecue, cylinder heads and crankcases.
Add on: - before, I would have cut from the side I could actually see. Well done.
As an adjunct, YOU are about the only person I’ve SEEN - maybe with the exception of Allen Millyard- ( there may be others I haven’t seen) on CZcams that use all the PPE required to protect themselves.
I cringe when I see people using grinders or drills or saws or hammers or etc etc with no eye or face or ear protection.
To me , that always reveals a lot about their attitude to their work.
Well done. You’ve always seemed consummately professional to me.
Thank you so much Nick for those very kind words of encouragement, I had to cut from the blind side as I only use a 4" disc on my grinder, a 9" disc would have meant I could cut from the visible side, but you know how the saying goes, 'measure twice, cut once' and take your time... thank you also on the kind fords for PPE, having suffered a hart attack last year, I work safer than ever now, eyesight and hearing is a gift that is not to be endangered lightly, and it only takes a second to end up with a life changing injury. PPE itself is a constant hidden expense of the Channel, not just gloves, but filters for the respirator and safety glasses, I go through 3 pairs a year, but it's an expense I'd never stint on (I also make sure my lovely camera assistant is also fully PPE'd at the same time for her health and safety too!). Thanks again for your kind feedback Nick, have a great weekend!
Another nicely done job Del. Everything is in the détails! I would have done the same cut as you did. Especially to disimulate the little oil feeder. You brought it to a really nice finish.
I don't comment really often but i never miss one épisode.
It's a nice project bike. I'm anxious to see how your engine will turn out!!
Keep it up!!
Thanks Hugues 👍, we're really glad you're enjoying the project, it's gonna be a great adventure!
Aluminum is very forgiving when trying to modify it. Polishes out beautifully as you demonstrated after the modification.
Looks a thousand times better than the standard case!
You’re a brave man- cutting from the ‘blind’ side and trusting your reference markings.
Having been bitten
Brilliant! That looks OEM. My personal tastes run to no matter how custom a mod is, if it looks OEM, that's what does the little happy dance visually in my head for some reason lol. :D
Thanks buddy, that's very kind, im happy with the results and glad to have made the first mod to the build..
So what do you do with the hole on the bottom towards the front?? I think it’s lined up in the cover w/the #4 cam front exhaust. Does Oil drip out of that hole in the cover or is that a breather hole or something thats cast in the cover?? I’ve seen vids where people Tig weld that hole up. Why? What’s it for. Does it affect anything cutting cover down & leaving hole on bottom of cover unplugged and open?
It’s always a puzzle when you decided to modify the bike… well… gotta see how it looks when you’re done…. I’m olde school guy, liked everything original but MAYBE you change my mind!! Lol 😂
I watched this few times. Just never thought of customizing like that… great job on metal fabrication.. polishing ect.. it’s Kwel!!
Anyone know the part number for that cam cover with oil channel? All the ones I see are either for 04 and up or the older sportys that don't have the oil channel.
Very labour intensive but how satisfying to complete, very nice job 👍
Thanks Andy 👍
I like how this turned out for you. I can see why this is a popular road to take. Especially true when someone can do it themselves and customizing these bikes is such a big culture. Any modification that doesn't take you to a parts dealer would be pretty popular!
Exactly my thoughts too sir.. adding accessories is ok, but genuine modification involves taking the factory parts and hacking into them, and of course,m far more satisfying too. i think this particular mod began its popularity within the Buell community, and has blossomed since then.. Take care and have a great weekend. D&Pxx
So now I can enjoy my Friday evening having had my Delboys Garage fix🍺
Nice one mate, thanks for your support.
That was great to watch. Having to wory about the cam angle also adds to the effort by what must be an extra 35%.I think leaving the edge with the form of the case will add to the strength as well as hide the oil feed like you say. Great effort and lovely work. Thanks that was most enjoyable :)
Glad you enjoyed it Tony, I'm really happy with the outcome, and looking forward to ploughing on through the project! Thanks for watching and taking the time to comment.
Just MORE FANTASTIC work from Dels bike shop !!! 👍🏻🤠🇺🇸
Thanks Robert👍. Glad you enjoyed it.
I cut mine down right to the edge, I wish I done mine like yours. There’s a little hole under mine that I had to weld, as it ended up spilling oil everywhere! Good work dell. I wish I can send you a pic of what mine looks like 👍
Hi buddy, sorry to hear that, just thought that the thickness of the case was a little thin to go too close, so I guess you've proved that that is a worry, but it sounds like yo got it fixed. You could send us a picture on the email, I'd love to see it : delboysgarage@yahoo.com
Ok, so great video on a very common mod, just wondering, why in Gods name would you do all this with the timing module in place? 5 simple terminals and it’s out??
Dear Del & Penny, you have the best motorcycle mechanics channel on CZcams.
Thank you so much for the sharing, inspiration, and good advice.
Thanks buddy, appreciate your kind words, have a great weekend!
Great job.
I thoroughly enjoy your videos Del , you are so methodical and diligent in your approach you have inspired me to tackle jobs on my own machine that I might have baulked at in the past
I feel the same!
That came out awesome!
Thanks buddy, glad you approve!
I'm liking your videos, Del, however I'm glad my bike is an '05 for this procedure (No ignition module there)
Talk about sneaking up on it, but as we all know it is easy to go past that point of return.
Yes mate.. and into a world of sorrow.
That was brave Del but end result as anticipated was 👍
Not seen that mod done before looks great. Loved your file cleaning on your wire wheel, I still use a file card lol. Looking forward to your next instalment. Take care stay safe.
Thanks 👍
Really wanting to do this on my 2010 Harley 48, I have another 2004 evo cam cover in great shape so I was wondering if you know if there would be any problems using the 2004 evo cover on the 2010 evo my thought process is 1 I can do a practice run and 2 bike will still have original cam cover as spare, any light you could shed would be most greatly appreciated
Sorry mate, I've no idea, I've never done such a change, or compared the two... all you could do is compare the part numbers with Harley and if they're the same part number, you'll know it's the same cover!
Nice mod. Your attention to detail is great.
Great to see someone use a proper mask for grinding aluminium. I see so many people use useless cloths masks or none at all. Scars the shit out of me.
What year model is this cam cover from? I want to use an older style like the one you are so that I can use a stand-alone ignition and do away with the 2004 thru 2006 style electronic ignition and the associated Turns Signal Alarm deal. The older points style covers have different oil galleries at the to of the cover. The cover that you are using has the top of the case oil galleries like mine, but it is machined through the points cover, whereas behind my points cover is... nothing. Your cut-back looks great, by the way. Thanks for the video. Liked and subscribed
This engine is a 2003, the last of the rigid mount motors. ! Thank you for the sub, welcome aboard, much appreciated, and good luck with yours.. sounds like a fun project, so much of Harley's engineering is interchangeable with only small modifications needed at best. !
@@Moonfleet41 Thanks very much.
If you rub chalk into the teeth of the file it will reduce the aluminium clocking the file.
I did enjoy that. Hardly a HBO classic but i was glued to the tv.. Cheers & Thanks
Glad you enjoyed it mate, and we completely appreciate your very kind words... we work hard behind the scenes to deliver watchable and interesting, progressive content... so thank you!
6/15/2023 Very good liked it immensely .
Do you round any of your cylinders (and get rid of the boxy look)
Thank you , Del
Looks much better Del, it's going.to be a great build 👍
Turned out nice Del..
Was expecting the old klick of the fingers trick on the grinder disc change.🤣🤣
I did this mod last summer my god it was a messy job! I trim it all the way to the edge.
Excellent job my friend looks fantastic I'll bet 90 percent of the guys that do this job is nowhere near as precise as you are that is a fantastic job
Keep it between the mustard and mayo and rubber side down GBU later
Thank you Virgil, really appreciate your kind words... just can't work in a messy environment, so try to keep the place tidy! Have a great weekend Sir!
Great video Del & Penny. Very cool mod mate, job well done. Got to love a bit of grinding and filing, it's good for the soul LOL. Penny and you have a relaxing weekend and I hope you are getting some better weather. Take care, Cheers
Hi Del great job I always panic on that kind of work you cant put the metal back if you get it wrong Del you got it spot on mate a great weekend to you both
Thanks Dean, measure twice cut once aye, same as always.. glad you approve and always good to hear form you mate..
Your videos always help while I wait for the Michigan winter to go away so I can ride...
We have friends in Detroit and they've been telling us the same thing, roll on summer aye? Thanks for watching, plenty more to come!
Wow another fantastic vlog. I've been wrenching on my own bikes for over 30yrs and your methodical approach has taught me a lot. Never to old to learn eh :) I hadn't seen the cam cover mod before so very interesting. I like it a lot. I'm looking forward to seeing what you decided on for engine mods. The way you give a little smirk about what's to come makes me think it might be something pretty special, just like the build no doubt.
Hi Kevin, thank you for getting in touch, and thank you also for the kind credit of inspiring your projects too... but obviously it's your hands that does the work, sometimes all we need is a little encouragement from someone else! Really looking forward to this build, it's gonna take a fair while as I have so much planned, plus am also doing it 'old school' with a full raggedy dry build, then take it for inspection, then it'll come back to the garage and be torn back down to it's frame for a re-build with 'paint, polish and chrome' (well maybe not chrome lol)...
That came out great Del ! Looks like we will have to add Plastic Surgeon to your long list of skills. 😁 Thanks for letting us hang out with you in the shop. Much appreciated. 👍👍
Thanks Rick 👍, you'd be welcome any time as long as you bring cake... or chips!
@@Moonfleet41 Yet another common interest of ours...health food.😄😁🙃
Parfait beau travail 👏👍
Merci!
That’s on thing my sporty needs too 🤔
Go for it mate, let us know how you get on!
Nice job 👍👍
Thanks 👍
Vast improvement. Always nice to loose a bit of excess. Well done guys 👍🏻
Absolutely mate... who needs salad when you have a grinder..!
that should help with cooling the engine ! was that a basted file ?
Looks great. From Texas. Going to do mine now.
Good luck. Have fun! and thank you for your support.
Nice neat job as usual Sir!! Looks like it's going to be a lovely build.
Thanks Nick 👍
Looks neater and great work👌
Brilliant!
I would put a plug in an empty socket when power grinding/cutting, saves that fizzing and sparking noises.
Good point Andy..
Looks much neater and I guess there's a little weight saving thrown in for good measure.
Thanks mate, and Yeah, at least a pound in weight gone now..!
Epic..
Great job. I would trust my bike to you with closed eyes
Thank you for your kind faith sir.
So you've got hotel duvet covers as dust sheets ( how posh lol).
Saved a bit of weight too.
Suprised you haven't gone for an ultima ignition timer or have you .......
Have heard that a twin carb upgrade with big air intake will improve the torque as long as the cams are matched. Obviously new wismec pistons etc.
Are you going to balance the crank?
Ha ha, no they're curtains, got ten of them for 50p each from a charity shop.. awesome value aye.!
And yeah, at least a pound of metal out of the way, and let's face it ,a Harley needs all the weight loss it can get.!!lol
Looks great. If i had done that id most certanly have discreetly nicked the wiring harness for the ignition module with the grinder and then spend days trying to figure out why it wont run :D
Ha ha.. that was my biggest worry, but thankfully not a scratch and all good..
Once again, you've clued me in to another cool tool: the quick release angle grinder lock nut. It bears mentioning that a file card/brush will eliminate the need to take your files to the bench grinder to de-gall them (less than $20 for a quality Nicholson tool, and easier on your files). That said, your end result looked like it was originally made that way, and excellent work! You are a true craftsman.
Paul you are too kind, thank you for your generous words Sir, and also for the tip on the file brush.. i only ever press real lightly on the bench mop to clean the files out, as you're right, long term it can dull them.. Take care and enjoy your weekend.. Del.
Fair play, you've got some nice equipment going on. Been doing some filing myself recently, on gsxr rearsets, and removing the manufacturer's name and other unwanted casting noggles, from rear brake cylinder, etc. it's quite soothing. I go 400, then polishing mop, but if by hand 400,600,1200, mostly because that's what's hanging around! That casing looks sweet. nice one. Have a great day.
Sounds like a cool project mate, pretty much any bike can be 'finessed' to look better then factory. Good luck with it and have fun.
Simple, effective and useful! Nice to see it working well for you mate!
Thanks buddy👍
hmmm now you have my attention. Mod does look nice on the bike. Wondering how this turns out. Ten days for special order parts- I have not been so lucky lol. Been waiting a long time for my parts for my Harley makeover from Harley Davidson. Stuff has been trickling in. Take care Del
Thank you Mike, ain't it a pain waiting for parts delivery, apparently all the gaskets have arrived but not the piston kit or the carb kit yet, all still stuck in customs, but as long I've got something to get on with I don't mind waiting... loving the paint project, hope you're enjoying it buddy.
@@Moonfleet41 .. customs which I hated most!!
Nice one Derek. Can I add something, when you cut or fettling, aluminium try using a bit of Tallow, on your sanding pads and cutting disc. keep safe and ride on d;-)
Thanks Andrew.. good tip.!
Another great video Del, try a little WD40 or Paraffin on the file, may stop the swarf sticking in the teeth.
David, you genius, I heard that from my metalwork teacher when I was 15yrs old... it was obviously filed at the back as I'd completely forgotten it! ... and I already know that if you're scuffing sheet metal for a brushed finished with a Scotchpad, you lube it with WD40, I just didn't factor it in to the file, so thanks for the nudge mate, too many memories jumbled up in the ol' brain, must be old now as I'm obviously forgetting things!
@@Moonfleet41 No worries Del, i was 62 this week, and i can't remember last week, LOL
again good work del
Nice video. What about the sprocket cover?
Awesome job del ...I'm guessing a bobber!!
Thanks mate, and no, not a bobber, no plans for that at this point.
Precise cutting/modification,as if a CNC machine did the cut!
Thank you kindly Sir, very happy with the result!
Great video mate, I'm planning to do this to.my 1990 sportster 1200
Good luck mate, hope it goes well!
Nice 👍👍👍
Thank you! Cheers!
looks kewl. Liking that.
noticed a lot of safety notes you kept reiterating... lol.. The snowflake brigade throwing hand grenades again?
I've been watching the Indians, from India...not North America, using kit from the 1920s, making all kinds of stuff... and they all have 4 fingers and a thumb on each hand!!!! lmao
tis incredible!!
Hey buddy, yeah me too, i love watching them in open toe sandles working in an iron foundry...
Gotta say, never seen it done brother….. not that I’m aware anyway. Having seen your end result, I have to ask why? Why I’ve never seen it before that is, it looks so much better for what you’ve done. Good job.
Thanks Brother, i think it started out a while back as a Buell thing, and seems to have caught on a bit and like you say, looks a lot better than the boxy flat cover. Take care and have a great weekend both of you.. D&Px
@@Moonfleet41 With Buells the mod also stops the oil lines rubbing through as you can reroute them,might be the same with rubber mounted sportys
Great job. :)
Thanks for the visit
As always, nice Job Del. I'm pretty excited to see what is next. 😎✌🏼
Thanks mate 👍, lots more to come, and once the engine's built, we'll be tearing in to the bodywork and wheels and everything else...!
can you send a link to the torque tool you use to torque up engine casings (t handle allen) ?
Here you go. ! www.spanner-monkey.co.uk/Wiha-Torque-T-Handle-ST-Plus-TorqueVario-Set-29234?search=wiha%20torque%20vario&description=true
Wow, great job... Congrats 😉
Thank you! 😃
That looks so much better brother ! great job ! 👍 taking your time shaping it the way you want it to come out it's priceless! worth it , hope you get the parts soon ! keep up the great work brother , stay safe guys cheers from new york!🍷🍷🍺🍺
Thanks so much for your kind words of support as always brother 👍, we're glad you're enjoying the project, it's gonna be a fantastic journey, take care and have a great weekend both of you, with love and respect from us both!
I enjoyed that, Del!
Great Video A job well done Del 👏👏👌👍
Thanks Chris. Glad you enjoyed it!
Super cool Dell! Cette nouvelle aventure s'annonce passionnante! (Ha! Ha! Ha!... j'avoue avoir également pensé à Allen Millyard.)
merci beaucoup pour vos gentils mots d'encouragement, profitez de votre week-end mon ami
Another fantastic modification, Del! It's always a pleasure watching you work! I usually watch your videos when I get home and watching you craft is a fantastic way to relax. Hope you have a wonderful weekend!
Thank you so much for your kind words David, we're really glad you enjoy the content. Have a great weekend too and keep safe mate .
Now that looks really good, nice mod Delboy.:-)
Thanks mate 👍
Hey bud. Been following this build from day one. Trying to find the episode where you polish everything with the bench polisher. Have any links for the bench polisher and polishing compounds used. Thank you and keep up the amazing work.
Not everyone would strip an engine to polish the casings, specially the cam chest, but with this project I polished it all once it was back together and the centre parts painted, you could use a hand polisher like this: www.spanner-monkey.co.uk/cordless-polisher-kit-o71mm-12v-2-batteries-113642?search=cp1205kit&description=true it works very well.
@@Moonfleet41 That’s true. But I’m actually tearing my engine and front end completely down. That’s why I was asking about the bench polisher and polishing compounds you used. Thank you sir
Really nice custom job, Del. And a great video from you both. Have a great weekend!
Thank you for your kind words of encouragement, and same to you, enjoy your weekend.
Hello there , can I do this mod on my 2014 Sportster ? From Japan , James .
Yes James, it would be the same job on your bike.
Great video Del. I like the look of the cam cover modification. I know you have a budget but hoping for a stage 4 Screaming Eagle kit. Great message to live by.
That was the aim, and for a fuel injected bike that's almost possible as it's available in a 'kit", but for carb bikes this old, no such kit, just left to buy each component individually, which would have cost me more then the whole damn bike... but i have made a good choice i believe, aligned with the rest of the build budget, and hopefully still give me a great fun bike to ride.!
Who dares wins! What an ingenious modification Del. Like how you managed to bevel the edges slightly and achieve a mirror finish on the casing and edges. Some real graft involved but wow what a result. Looks top drawer. Really enjoying this project and already looking forward to the next episode. Have a brill weekend Del & Penny. 🥳👋🏻🇸🇪🇬🇧☘️
@@clark7169 Hey Paul, thanks buddy, It's really therapeutic getting involved in the first actual fabrication of the build.. Have a great weekend too and keep safe sir.. D&Px
Great video, all that filing took me me back to metal work at school,one of my teachers used to call flies the poor man's milling machine 🤣🤣
@@chrisbrittle4158 Me too Chris, our metalwork teacher made us 'earn' the right to use things like the lathe and mill by hours of practice with a hand file first to understand the motor skills needed to make a good result and also a good technique with the file to keep it healthy and not dull it..
Not bad, not bad at all. Love your modification, Del. Have a great weekend, Günter from Nürnberg/Germany
Lovely job Del. I’m just waiting for my Andrews N4 Cams to arrive with the rear shocks and front monotube cartridges. You can’t beat a modded Sportster!!
Sounds great Mark, and should be a handful when you're done.. Thanks for watching mate and good luck with your build.
Awesome Job Del 👏 👍 Penny and You Del Have A Wonderful weekend and Always Ride Safe.Tell Penny I Said Hello 🦋🐞PS How is Penny doing? Is Penny all Good.
Hey Paul, Thank you for your kind words, Penny is safe and well, working hard on her recovery and physio, and hopes to be back on her bike for the summer.. She says hi and thank you for your kind support.. Enjoy your weekend too and keep safe. D&Pxx
Looks great Del. Very interesting look. I really like that look. Finally got my true dual Cobra pipes on the Heritage. I will send you a pic.
Congratulations buddy, ainit always the best when we fit new parts.. ive love to see a pic or two if you can drop 'em in the email, Have a great weekend and keep safe. D&Px
Wish you could come to the United States and do a build for your channel...you can use my 14' heritage;-)
That'd be cool, thanks so much for your kind faith and support.
That file cleaning tip is genius! Nice work Del.
Thanks Mark. Glad you like it!
What year is it?
2003
Nice work - it looks real nice cut down.
I wouldn't be able to stop my hands shaking if I were attacking a £200+ casing with my angle grinder - lol.
Keep up the great vids brother!
Blimey.. is that how much they cost... glad i didn't know..lol! But seriously, cut wide and grind back, no problem if you take yer time aye..!
I take for granite you’re gonna make a bobber out of it
No mate, not at this point, have a few other ideas to run with.
It sure looks like you did a nice professional job trimming down that cam cover. I guess my question is, what are you planning on doing about that butt ugly belt pully?
Grandpa Fumblefingers
Your CZcams friend in southeast Arizona
Hey Grandpa! I have a great plan for the belt pulley, I'm going to aim it in the trash, or I may convert it to a doorstop, and in it's place, will go a nice shiny chain sprocket with a see through cover! Thank you for your kind support, I would say enjoy the sunshine weekend, but I guess living in AZ you already are!
@@Moonfleet41 I approve :)
Enjoyed this very much, Del. Lots of work but great outcome! BTW, loved the saying about strength in the vid’s opening segment… very true indeed. Reminds me of those stories about mothers lifting cars (by themselves) off a trapped child… with super human strength. Good one!
Have a great weekend there- hope the two of you get out for a ride!
🏍👍🏍
Thanks Gary, glad you approve, simple sentiments i guess, just sharing a thought for the day. have a great weekend too, we're off for a ride if we can, got to get some miles under the wheels while the weather here is really nice at the moment.
@@Moonfleet41 Great - enjoy it! Hi to Penny! 😎
Del. Please address the swing arm bushings and engine mounts. I need to do this too. Rather watch you first
This will be a long term project Richard, I'll be doing all the bushings and wheel bearings, head bearings, fork seals etc., but this is a solid mount motor, not a rubber mount, so there's nothing much to replace there... but the motor will come out later, once the dry build is finished, so I can paint the frame!
@@Moonfleet41 awesome! Forgot it was not a rubber mount.
Wow! It looks like it should have been that way from the start. Plus a few pounds of weight shed. Don't go adding it back with pints from the pub. 😉
Have a great weekend, Del & Penny!
You are right Logan, at least a pound of metal gone now... so ill have to stick with the low fat pasties now.!
Makes me wish I had a HD to mod 🙂
Looking really good there Del - have passed your vid forward to a sporty owner who’s been chopping his about for years! - there’ll be nothing left of it one day!
Thanks mate.. i love the Sportster community, so supportive of each other and always happy to share a mod or idea.. Thanks for sending it, glad it could help.
Great mod. I'm getting ready to do a sportster project and I think I might have to try it. Great video, as always.
Go for it mate, and have fun.
Are those gear case castings a throw-back to some previous model in their range? If not, why do Harley throw good metal away by casting them all with this outrageous copy of Robbie the Robot's alternate week-end genitalia. Strange innit : )xx
Ha ha Robbie the Robot !!!! showing yer age mate...!lol
Kryton's mess kit was just a 'Cann Summers' copy too : )