6) Motorcycle Parts Have Arrived

How will the new parts fit?

One of the major issues I have found in trying to go none standard, off the normal path, the road never taken is no one know what you want when you try to order parts. The internet is a great way to shop for any and all parts. You can find anything you just have to know what you want and what it was designed for.

You may recall my project is to take a touring bike (GL1500 Interstate) and turn it into a Cruiser similar to this;

With a standard fuel tank, (not the faeux tank on the Honda), a frame mounted fairing, (smaller than the Honda) and simpler overall than the Honda Goldwing 1500 which is a big motorcycle.

In the last Blog (#5) I discuss the disassemble and the removal of the fuel tank which was a challenge and the new Fatboy tank I ordered off Ebay. When the new tank arrived the challenge of making things fits began.

So I quickly took the new tank to see how it was going to fit. I knew there was going to be impact but I was hoping maybe minor tank modification or air box changes would be the extent. Well, no.

I was once told by one of my supervisor, "hope is not a strategy." This is so true. You can hope something will work but if you have not done the necessary research it comes out to be more of a guess. So I know I wanted a fatboy styled fuel tank and I kinda hoped (guessed) it would be OK. But I also knew I had to make a leap to see where and what I needed to do.  So now I could scope out how I can modify the air intake system and fold the Harley parts into my project.

My scoping started on the internet looking at aftermarket air intake systems. The system I tunneled in on was those put together by K&N air systems. I found one that I thought could have a chance of fitting into the frame. It looked good, small and simple, but I needed actual dimensions. I initially searched online specifications and found out the size of the shipping box, 12" x 12" x 20". Well not really the dimension I need.

Next I watched a few U-Tubes hoping for scale. So how big is a normal hand? That did not work either. So I decided to go right to the horse. I logged on to the K&N web page and sent them an E-mail asking for the physical dimension of their 57s-9500 air filter system and waited for the response. The response I got was they did not know!!

How can they not know! I continued to look at this air system and really liked it. So again I logged on the K&N web page and went to a Live Chat and again asked for the overall dimensions. And again the responses was they do not know. The only real information they have is what cars their systems will and will not work fit. I got a little frustrated and responded that it must be necessary to buy the unit for $135 to find out actually how big it is. At that point he guessed 7 1/2" wide and 8" long. Which would fit, so I order it, "hoping" he was close.

Well the 57s-9500 air filter will fit perfectly. Now I have a fuel tank and the air filter that will be the basis of the transition. I just needed to attach the air filter to the carburetor and make that fit under the fatboy fuel tank. 

This is a picture showing the space under the fuel tank and the top of the carburetors. You can see there is less than two inches of clearance and a very odd shaped carburetor flange.

So it was time to get creative. My first thought was to have a flange manufactured that would mate up with the carburetor and than piped to the air filter. This would be very elegant and is an option. But than I found a Honda Goldwing 1500 stock air filter box on Ebay for $4 and I had another idea. Can I modify the stock air filter box to fit under the tank and still tie it to the K&N air filter. And when the stock air filter arrived the cutting began and.......

K&N Air Box in a Goldwing 1500

I was also able to build a aluminum box behind the K&N box where I want to move the coils and other relays.

Honda Goldwing 1500 Cruiser project

 I have also been researching the electronics and instruments I am going to need, like the speedometer and fuel level indication. So what I have decided to do is buy a new fuel tank with a chrome dash, ignition switch, as well as fuel level sensor and other indicators/instruments. Once I have the new tank I will have it modified to sit lower on the bike for a sleeker look and also allow a clean fit underneath. Next step will be permanently mount air box, route plug wires to the new coil location, buy the right fuel tank and find a weld shop that can weld/modify a fuel tank.  For sure that is not me.