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Discussion Starter #1
This thread is dedicated to all those who want to build a custom ride but dont have the cash to hire some custom shop and a ton of cash laying around. This whole rebuild was done with two hammers a tig welder and 100 dollars worth of sheet metal thats about it. This was my 1989 FXRS Lowrider pre crash. I loved this bike and just couldn't let it die. I was going around a sharp bend in the road on the brakes and I ran over a sewer cap with some sand on it. The front wheel let loose like it was on ice and I went down at about 40 mph. The forward controls put my leg in a bad spot and my left leg went under the bike and the upper shock bolt shattered my lower left leg. The plate screws and bolts it took to put it back together is a whole other thread with of info. So here I am over 5 months on crutches one month on a cane and one month walking with a severe limp I still ain't walking right but getting better. About a month ago I decided I wanted to resurrect the wreckage of my beloved hog.
 

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good luck to you, looking forward to see pics of your progress
 

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Discussion Starter #3
where to start

It took some long hard thinking of what to do with this bike. obviously first thing was to dismantle the whole bike and inspect the frame for being bent or twisted, lucky for me everything looked ok so now it was design time. It starts with some thinking first of what you want in a motorcycle, do you want a chopper, bobber, pro street, bagger or some hybrid of some sort. I want a bike i can throw around and handling was the primary goal. This was the reason i always wanted an FXR. Knowing that modifying the frame geometry was out of the question this bike already had the handling i was looking for. I also love the cafe racer look and wanted to come up with a modern take on that style. When i came up with where i wanted to go with it. I drew on a piece of scrap paper some rough sketches of some designs. don't bother getting too technical with the drawings when you start building you kind of just let it happen. It' more fun that way.
 

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Thank you sir. i have gotten pretty far already just decided to share my experience with all and will keep on going till i catch up. the end result was worth it. enjoy!
 

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Sorry to hear about your accident. I hope you literally and figuratively get back on your feet, soon. And I will look forward to reading about your progress in rebuilding the bike again.

BTW, I know Massapequa well. I grew up in Brooklyn and had lots of family and friends on the island.
 

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Discussion Starter #7
Let the beating begin

So here's the deal i'm a welder by trade so i have experience but not with sheet metal at all, i work and heavy structural steel and thick plate arc welding not tig and sheet metal. So anybody out there can do this. You have to decide what gauge to make it out of the thinner it is the lighter and easier it will be to work but it flimsy and will require bracing and support the heavier it is the harder it is to work and it can be heavy. I chose 16 gauge for everything fairly easy to work and strong as hell. this thickness won't dent up and realy isnt to heavy. I got a 3x8 sheet for fifty bucks. What you will need is cardboard lots of it. poster board the thin stuff is best so you can bend it easy and it cuts well for making templates. A good pair of scissors some razor blades and some sharp pencils. Two or three hammers one good size rubber mallet round the corners of it on a grinder a medium and a small ballpeen hammer. A handheld grinder with sand paper disks like 80 grit and acces to a bandsaw or plasma cutter would be great. If not get a hold of a jigsaw with metal blades. thats about it.
 

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Discussion Starter #8
So lets face it the fxr wasnt nicknamed the uglyglide for nothing everybody hates the "foriegn" bike triangle frame on the side and other than the tank there isn't much room for paint. I dont think its ugly but i did want more paint area. So with that said i wanted to cover the sides of the bike and sleek it up a bit. I also wanted to keep the cafe racer theme going. so sketch out your cardboard design and cut it out you can bend it around and check fit. them trace it on the metal and cut it out. The design i had rolled arond the frame so i used a piece of pipe to curl the tail over to get it close use the rubber mallet so you dont dent it up bad and slowly beat it around the pipe till it is close. then after bolting the shock through it and lampming it in place i just beat the rest around the frame to form it. do both sides then cut and fit the other side. i thend put the rear plate underneath for tail light. this held it in shape and made it really strong.:beatdh:
 

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Back in July of 2011, I went down, at the same speed, same leg, lower left, and had the same hardware. I healed up very quickly. They told me I would be lucky to go back to work in 6-8 months on light duty, I was back in 3 on full duty. Bust your ass in rehab, it will pay off. The other side of it is, as soon as you can, have them take all the metal out. They told me it would be there for the rest of my life. BULLSHIT! It's my leg and told them to remove every bit of scrap. They did, and I feel terrific! I'm not, nor do I ever expect to be 100%, BUT I feel so much closer now, then I ever did with the metal.

And good to see you getting back on the horse!
 

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Discussion Starter #11
so now that the rear fender base was done now you can see the seat is not hitting in the rear. I had to build up the area under it. I traced with a pencil along the edge of the seat and cut out the area under the seat tail and made more templates and cut them out of steel. I made them a half inch to high o purpose and rolled the edges over using a crescent wrench to make the lip that seat will sit on a wall just behind the seat that held up the steel tapering off in a following slope of the seat to the tip of the fender. then i floor in the glove box yes i said glove box. I always wanted a little storage spot and with this design it worked perfect! My girl loves to ride and that mustang seat sucks because she slides off the ass when i drive like me so i wanted to make a removable sissy bar that wouldn't interfere with the look of the bike. so i welded in some angle clips with nuts welded to them. So two 3/8 bolts ant it pops right off. i made the sissy bar out of 1/4 x 2 stainless for strength and yet it is very thin from the side.
 

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Thanks beardo. that's great mine was literally shattered i'll attach some CT scans was told if it didn't take they would have had to cut it off but luckily that didn't happen. you can see how bad it was.
How did you get them to send you your scans? I asked and was told that was a no go. Mine was eerily similiar. Did your fibula snap up high, too?

LOL I told them to chop mine off! Multiple times! Figured I would be faster without the added weight!
 

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Yup, that is an ugly ankle, my brother did one 30 years ago and walks with a pretty good limp. It does not slow him down tho.
Nice work by the way
 

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Yup, that is an ugly ankle, my brother did one 30 years ago and walks with a pretty good limp. It does not slow him down tho.
Nice work by the way
 

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Discussion Starter #16
surprisingly my fibula did not break. the damage would not have been bad if the upper shock bolt didn't hit dead on the upper ankle. the entire weight of bike hit it on that spot. if the timing was a little off probably would have gotten away light. I got a copy from medical records department cost five bucks on CD on there was x-rays and CT scans. this happened on June 30 so i'm just at seven moths out
 

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Discussion Starter #17
Body work time

So i got the rough body work done. I used short hair bondo for strength. I sanded the whole tail down with 80 grit roughed it up real good and wiped it with denatured alcohol to clean it and aplied the bondo and shaped it with 80 grit while it was hardening that **** is tough and if you wait till it's dry its like sanding steel so rough sand it quick as it starts hardening. I wasn't going for perfection yet just shape plus im don tdone shaping the rest of the pannel yet.
 

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Discussion Starter #18
Chin spoiler

Sticking to the cafe style i wanted a chin spoiler. I know that they are mostly for looks but i wanted to design a fully functional one like a big ram air scoop. ive seen the cheesy after market ones and didn't think they were nice for the look i was going for and i hate plastic on a hog. So back to drawing and making templates i also didn't want to leave out cooling the regulator so bring on the fire, steel and hammers. this is what i came up with.
 

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Discussion Starter #20
Custom Fuel tank

Ok now for the part i was waiting for. There are not many choices for an FXR tank out there. the stock one got a big old dent when i bounced of the curb on my slide out of the curve. I decided i wanted to make my own creation. step one build the tunnel. i could have had this folded in a brake but i'm a stupid caveman and was on a quest to do everything with a hammer and no one can see the tunnel any way so after some fun with a hammer i got it done. I never liked all that frame sticking out on the front past the tank and there was four olt holes in the front with plastic plugs in them in the front so that is what i wanted to mount to with the new tank cover up all that ugly stuff up there. the stock tank came down so far i couldn't even wipe off the valve covers so i followed the frame line under the tank so it should have allot more room this way give that chopper look to it also. the tunnel was left a little long down there at first but was trimmed later. then the mounting supports were made from 3/16 plate for strenth and go into the tunnel a ways for strength.
 

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