Cut that ugly sprocket cover!

Here’s my take on chopping a Sportster sprocket cover. First I used some black tape to get an idea of what I wanted to do. Then I had at it with a jigsaw, drill and grinders, followed by some sanding and buffing. It still needs some more sanding and buffing but I’ll wait until the finishing stage.

Sportster Custom Sprocket CoverSportster Custom Sprocket CoverSportster Custom Sprocket CoverSportster Custom Sprocket CoverSportster Custom Sprocket CoverSportster Custom Sprocket Cover

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Homemade Custom Motorcycle Battery Box

What’s up y’all? Long time no post. Sorry about that. Got caught up at one of those job things. Anyway…

Below are some photos of the battery box. After making a cardboard dummy and getting all the measurements correct, I jumped on the computer and used Adobe Illustrator to layout the design. I then printed it onto a mailing label and stuck it on some 1/8″ steel plate. Using the band saw I cut out the shapes. Like butter baby!

Motorcycle Battery Box DesignCutting Custom Motorcycle Battery Box

For the holes I just used the drill press and a stepped bit. A spray bottle and water helps to keep the bit and metal cool while drilling.

Cutting Homemade Custom Motorcycle Battery BoxBuilding a Homemade Custom Motorcycle Battery Box

After the pieces were all cut and filed it was just a matter of tack welding and making sure everything was square. The angle magnets were a big help in positioning things for welding.

Welding a Homemade Custom Motorcycle Battery BoxWelding a Homemade Custom Motorcycle Battery Box

I bent up some aluminum sheet to cover the battery but I might not use it. It’ll either be polished aluminum around the battery with the outer box painted whatever I decide for the frame or just lose the aluminum and spray the battery black and chrome the battery box.

Homemade Custom Motorcycle Battery Box DesignWelding and grinding a Homemade Custom Motorcycle Battery Box

After some sanding and grinding it looks pretty good. Need to fill in some spots before it gets finished.

Homemade Custom Motorcycle Battery Box Design

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Do it yourself welding table plans

If you’re going to be fabricating some chopper parts your going to need a welding table. I found these welding table plans on the Lincoln Electric website. Nothing too fancy, but gets the job done. It’ll also come in handy when using a torch to bend metal.

Do it yourself wellding tableDo it yourself welding tableDo it yourself welding tableDo it yourself welding tableDo it yourself welding tableDo it yourself welding table

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