DIY Network

Stripping the Bike From "Classic Rides" episode DCLR-101

In the first two segments the project 1965 Harley-Davidson Electra Glide was evaluated, and in the last segment a chassis dynamometer test was performed. Then the restoration plan was hatched by host Kevin Tetz and Harley-Davidson master mechanic Bill "Dunk" Dunkelberger.

Now it's time to strip the bike and begin the restoration!

Note that some of the parts on the project bike are too far gone to repair, such as the windshield (figure A), so they will be replaced entirely. Many of the parts, however, can be salvaged, refurbished and put back on the bike.

Tip: If you're considering a motorcycle restoration project, it's a great idea to have a lift (figure B) for easy access all the way around the cycle.

Figure A

Figure B

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	Figure C
	Figure D
	Figure E

Getting Started

• The first thing to go is the pogo seat (figure C), which means it bounces up and down, on the bike. It will be replaced with a lower frame-mounted seat. To remove the seat, remove the mounting bolts and brackets as needed. On the project bike a safety wire was securing the seat, so it had to be removed.

  Note: When doing a restoration project, don't throw anything away. Even if you think it's junk, these are antiques and there are always user serviceable parts attached to them somewhere that can probably be refurbished.

  For example, even though the windshield is broken on the project bike, the mounting brackets are almost worth their weight in gold.

• The saddlebags must come off and will be replaced with new ones.

• The exhaust must also come off because it's loose at the head (figure D), which will cause leaking. The whole exhaust system will be replaced except for the head pipe, as mentioned in the previous segment.

• The frayed brake cable is removed next and will be replaced.

  Note: One of the major advantages of working on a vintage Harley-Davidson is that you can use standard tools instead of metric. And many of the fasteners and parts are still used on the new Harley's and are readily available.

• The last thing to be removed is the gas tank. The fuel lines are clamped off and cut since they'll be replaced with stainless steel lines. Then the gas tank mounting bolts are loosened and removed. For this particular model there are two separate tanks (figure E). One of the two tanks was leaking so both will be replaced and given correct 1965 Electra Glide paint jobs.

The bike is stripped and on the next episode of Classic Rides, Kevin and Dunk will dig into the restoration by starting with the carburetion and fuel system and then upgrading the camshaft.

RESOURCES :

Harley-Davidson USA Information
Harley-Davidson USA
3700 W. Juneau Ave.
Milwaukee, WI 53208
Customer Service: 414-343-4056
Website: www.harley-davidson.com

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

Knoxville Harley-Davidson Information
Knoxville Harley-Davidson/Buell
Website: www.HarleyofKnoxville.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Motorcycle Hall of Fame Museum Information
Motorcycle Hall of Fame / American Motorcyclist Association
13515 Yarmouth Dr.
Pickerington, Ohio 43147
Phone: 614-856-2222
Fax: 614-856-2221
E-mail: info@motorcyclemuseum.org
Website: www.ama-cycle.org/museum/

Ultimate Harley-Davidson
0789499746
Hugo Wilson
(October, 2003)
To order this title from Amazon, click here.
Dorling Kindersley / DK Publishing

Hugo Wilson's Hot Bikes
0751336947
Hugo Wilson
To order this title from Amazon, click here.
Penguin Books

The Harley-Davidson Century
0760311552
Darwin Holmstrom
(September, 2002)
To order this title from Amazon, click here.
Motorbooks International

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com