Glenn sent me a few photos from the old days and one that got my attention was a shot of us building a Sportster in the living room of the shack we used to live in. Having a living room to work in was a luxury because prior to renting the shack I was homeless. I had an old Chevy truck with a bench seat that I could stretch out enough to get some sleep and I had a job that let me take a dry bath in the restroom after work. But when Admiralty Marine closed its doors for the evening I was on my own until the next morning. The boss let me know that the situation couldn’t go on forever and that I really needed to find a place to live.
It wasn’t so much lack of money. I was working a lot of hours, but I was only 19 and landlords didn’t want to rent to a greasy, punk kid. I can’t blame them. I would do the same thing myself. Finally a co-worker who was a full-fledged adult vouched for me when his landlord had a vacancy next door. I shaved, dry-bathed, put on clean clothes and did everything I could do to look like a respectable young man with a future. I’ll be dammed if it didn’t work. I was in after paying first, last and a deposit. Cash.
After waiting for the dust to settle the first thing I did was to rebuild my Sportster in the living room. When I bought the 1968 Sportster I was kind of shocked at how archaic the motorcycle felt. It was cool and all but the front end was so wobbly it felt like silly string and the front brake might as well have been deleted and an AM/FM radio installed in its place for all the stopping it would do.
The engine seemed to run well but I was going to ride across country on the thing, so a freshen-up was in order. I don’t know if it was a good idea because the 900cc V-Twin had some strange things going on inside and I was destined to do even more stupid stuff to the poor bike.
Someone had replaced the stock Harley intake valves with huge, unknown-origin valves. The valves were so big they had to cut the seat into the dome of the combustion chamber. Once the giant valves were removed the old seats were revealed along with the stock porting. The only advantage I could see to the big valves was a bump in compression ratio due to the valves occupying more space in the combustion chamber and the circumference increase giving slightly more flow when the valve first popped open. Once into the lift though the stock ports would probably be the limiting factor.
I wasn’t having any of it. I bought standard Harley valves and guides and set about putting things right. Admiralty Marine had a Sioux valve grinding kit so I could do all the work myself. After the seats were re-cut to fit the new valves the installed height was wrong so I had to trim the ends of the valves and shim the springs. The heads were a mess.
The Sportster’s high dome pistons were ok so a quick hone job and a set of rings finished off the top end. After that you’d think I’d leave the engine alone but I had to have a tin primary cover like the XR750 flat trackers ran.
Opening and consuming a whole ‘nother can of worms, I had to get rid of the crankshaft’s spring and ramp style compensating sprocket. The compensating sprocket absorbs the 45-degree V-Twin’s power pulses before sending smooth, less spikey power on to the clutch basket, gearbox and rear sprocket. This vital part stuck out way toofar for my tin primary so into the trash it went.
A solid front sprocket was fitted to the crankshaft and the tin primary would still not fit so I had to make a 3/8’ aluminum spacer the same size and shape as the primary cover gasket. The ’68 XLH was electric start but I wanted to eliminate as much weight as possible. At an independent Harley shop I swapped the starter motor, big battery box and oil tank for a kick-start shaft, gears and kick lever. You can anticipate the next problem: the electric-start primary case had a square-ish hump on the back to accommodate the starter Bendix. I had to weld a flat metal part onto the tin primary to cover the hole.
Without an XLH-style starter motor there was another gaping hole on the other side of crankcase. I blanked off the hole where the electric starter fit with a large chunk of angle aluminum that doubled as a battery box for the much smaller kick-only battery. Now the engine was ready to slot back into the frame. And that’s yet another can of worms I’ll write about later.
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