Harley-Davidson cafe racer Sportster PROJECT

Two years ago, Russell purchased the 1998 model Harley-Davidson Sportster that would ultimately become this café racer v-twin. Bought primarily for its motor and running gear, Russell had planned to use the Harley mechanicals in a replica Manx Norton frame designed & built in the US specifically to accommodate the Sportster motor.

Unfortunately, Russell was burned by the frame supplier, who didn't honour payment with goods, so the replica frame he'd initially purchased was sold to recoup some of the losses, and the café racers were built using their stock H-D frames.

"I had already built a café sportster and decided to source the replica Norton tank and seat from UK and build another one," Russell said.

While the first build was pretty complex, with extensive work done to the engine, suspension and brakes, Russell decided to keep this one simple - at least that was the plan!

"First job was to replace the damaged parts and register the bike," Russell explained. "As luck would have it, most of the items needed were left over from the first café build, so it was relatively simple to add the standard parts. Roadworthy and registration - while it was still a 'Harley' - was a simple process."

This clever approach gave Russell the means to road test the bike in standard trim and make sure there were no shortcomings in the mechanicals. Satisfied that everything was up to scratch, Russell then addressed each part of the bike in turn, what Russell calls a 'rolling custom,' that allows him to road test each phase of the build and make adjustments and improvements as required before moving on to the next phase.

Job one on this project was the exhaust. The Supertrapp pipes and silencers Russell got a hold of were created for a later model Sportster with the rubber engine mounts. That in turn meant the bends and lengths in the XR1000-style pipes didn't quite match the configuration of his earlier model Sportster engine and frame. The fiddling to get this right was worth it, though, as the Supertrapps not only look great, but sound awesome, too.

"I love the sound of the Supertrapp pipes," Russell said. "They don't have the standard 'potato potato' sound that Harley is known for. Instead, the Supertrapps give the deepest rumble I've ever heard in a Harley, and I instantly fell in love with them."

Combined with a Screamin' Eagle air cleaner, the first test ride with the Supertrapps in place revealed their position would cause a problem when rearset pegs were fitted. "I could foresee a leg burning problem, so I sourced and applied the heat wrap. Problem solved!" Russell explained.

Next job on the list were the aforementioned rearsets, as well as a braided rear brake line, alloy clip-on handlebars, and a new and brilliant head light/speedo lowering bracket, which was sourced from Shane Sorensen at Chainsikle in the US.
"Shanes gear is great quality and a reasonable price," Russell said. "That's partly why, on this build, I decided to buy Shane's gear instead of making my own as in the previous build."

Next up were the tank and seat. The Manx Norton-style fibreglass tank was made to suit an Evo Sportster, with the fuel taps carefully positioned so they fit neatly with the engine plumbing. Brackets to mount the take had to be made up and welded to the frame, but the café racer seat brackets fasten to the twin rear shock mounts and original seat position. This made things a little easier, but Russell said fitting both the seat and tank still took the best part of a day to get right.

Before fitting the tank, Russell added some chemical tank liner to prevent fuel attacking the fibreglass, then added a pair of new English taps. With the tank, clip-ons, rearsets, brake lines and headlight bracket fitted, it was time for some more on-road testing.

"Everything worked in unison brilliantly," Russell said. "The only adjustments needed were to change the position of the gear lever to suit my riding position."

With the front end sorted, Russell next turned his attention to the back. The rear guard was masked and cut high, level with the supporting frame. This suited the café racer look and also meant the rear guard brackets could be retained. A replica Lucas taillight was fitted to this bobbed guard, while a pair of small rear indicators were added to the guard brackets.

"I went for globe types and found I didn't have to change in indicator controller, as is required to run led indicators," Russell said.

A faulty regulator on the ignition coil was identified, thanks to testing by Small Coil Rewinds, and replaced with a new unit.

So, with all the tinware, mechanicals and electricals sorted and working in unison (after another test ride!) it was time for paint. Russell's first café racer Harley was painted black with gold metal flake pinstriping. Inspired by the Manx Nortons of the 50s, Russell decided to go for a metal flake silver on this build.

"I wanted to do my own painting this time," Russell explained. "Which is a challenge, as I'm a very impatient painter and get into trouble by rushing things! So I went down to Darby Paints in Geelong and loaded up with all the necessary gear and plenty of helpful advice.

"I watched some YouTube videos on applying acrylic paint, picked a nice calm day without any wind and got right to it," Russell said. "When I checked the date on a can of clear I had, I realised it was four years since swinging the spray gun, so nervous excitement was the go!"

By his own estimation, Russell said the result of his home-made paint job turned out pretty good. With everything put back together, the alloy polished and bike cleaned up, Russell said it looked even better. "BANG - what a look!!" he said. Geelong Auto Image made up the checker stripe stickers, while the other finishing touch, an HD logo rendered in Vincent-HRD style, was the work of Matt at National Signs.

Close to completion, this project, as projects often do, presented Russell with a final hurdle to clear.

"The Monza-type fuel cap on the tank would weep fuel when the tank was full, and the closing catch would occasionally let go," Russell said.

"I managed to get the cap off and fix the problems with a little fettling with the Dremel. When knocking out the poll pin on the tank cap, (the pin must have been locked in place with some expanding pincer type pliers), it broke one of the tangs holding it on."

This was no easy fix. Getting the tank from the UK took months and months in the first place, so Russell wasn't keen on waiting for another one. Solution?

"The tang was put back with a miniature self-tapper and some glue. The cap was fitted and works fine. It's not very noticeable, but it's there. For me, it was a major bummer on what was an almost perfect customisation within my own personal brief."

Russell said that next time, if there is one, he'll drill the roll pin out. Lesson learned!

Despite the last minute dramas, Russell said the finished result was surprisingly comfortable to ride. That was put to the test on a 400 km trip. Russ said both the bike and 'his old bod' handled it well! ,

"The bike has a stunning appearance. You can see people doing the 'Linda Blair' - turning their heads backwards as you ride past and they are trying to figure out what you're riding," Russell laughed.

"I consider my idea of not going overboard with motor mods paid off. The bike is best to ride when it's not rushed, what I mean is the gear change is relatively slow, the clutch is (by today's standards) slow, too, so I simply enjoyed riding casually and had more pleasure than trying to ride it like I stole it."

It doesn't compare to a modern sportsbike, of course, but Russell says that's not what this machine is about.

"You just need to love the look, the sound, the torque and pulling power of the bike's big V twin, knowing you have one of a kind café bike."

For this project, Russell extended thanks to:
Geelong Auto Image, Newtown
Matt at National Signs & Flags, Moolap, Geelong
Darby Paints, Geelong
Peter at Road and River Motorcycles, Newtown, Geelong. An expert on tyre advice and fitting, R&R also attended the two roadworthys obtained (one for registration and one for transfer)
Bert at Small Coil Rewinds, North Geelong. Bert tested the charging system to discover a faulty regulator

POSTSCRIPT
Since originally contacting us about this second café racer custom, Russell put the bike on the market. It's now gone to a good home in Queensland.