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Official Harley-Davidson Fat Boy Build Diary Stages 76-77 Options
arpurchase
#1 Posted : 19 October 2015 21:18:57

Rank: Super-Elite

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Joined: 27/09/2011
Posts: 15,108
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Location: Dudley
Pack 24 contains stages 76-77.

Stage 76 contains the pillion backrest.

For this stage you will need the left footrest from stage 33 and the kickstand from stage 43.

Take the kickstand and insert the hook of the spring into the mounting hole then place the round end into the slot on the footrest. Next place the assembly onto the frame lining up the stud with the hole and then use a 'F' type screw to fix the footrest to the frame. Now fix the other end of the spring to the mounting hole on the footrest, check that the kickstand operates correctly if it is a little tight loosen the screw by half a turn until it functions in the correct manner.

Store the assembled and unused parts safely in a bag labeled with the stage number for future use.
arpurchase attached the following image(s):
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Current builds:-C57,Zero, Lamborghini Countach, Caldercraft HMS Agamemnon,Robi,R2-D2, MFH Cobra .

arpurchase
#2 Posted : 19 October 2015 21:30:10

Rank: Super-Elite

Build-Diary Medal: Build-Diary Medal of HonourPublisher Medal: Article published MedalActive Service Medal: 500 post active service MedalPurple Medal: Super active service medal for 1000 postsRed Medal: Red MedalTurquoise Medal: Turquoise Medal for model making know-how contributionOutstanding Build: An award for an outstanding build
Groups: Registered, Moderator, Official Builds, Global Forum Support, Administrators

Joined: 27/09/2011
Posts: 15,108
Points: 45,871
Location: Dudley
Stage 77 contains the windshield.

This last stage is where we will fit all the parts received in earlier stages and safely stored until now.

Take the fuel tap from stage 61 and push it into its mounting hole on the left side of the tank base then take the stickers from stages 7 and 53, the stage 7 sticker is applied to the air filter and the other two stickers from stage 53 to the front right frame. Now take the coil from stage 42 and place it on to its mounting lug, from stage 65 you will now need cables 'E' and 'D'. Take cable 'D' and push the stub end into the uppermost hole in the coil side then place the other end into the hole on the top of the rear cylinder head, cable 'E' is attached to the lower hole in the coil and the other end into the front cylinder head.

Next you will need the rear bike assembly, the front forks and the axle from stage 40, offer up the fork assembly to the frame and line up the holes then use the axle to join them both together , fix the axle in place with the nut. Take cable 'G' from stage 65 and glue the blank end into the hole in the left handle with a dab of superglue then run the cable through the forks and down to the transmission housing and glue the lug end into the hole there.

Now take the front brake hose that is fixed to the front caliper and insert the end into the brake master cylinder. Next from stage 65 take cables 'A' and 'B' insert cable 'A' into the bottom of the right handle next to the switch and cable 'B' in the other hole under the handle then run both cables along to the front of the fuel tank bottom and insert the ends into the two central holes there. Cable 'F' from stage 65 is used next attach it to the hole in the bottom of the left fork run it up through the fender support and into the last hole in the fuel tank base at the front next to the other two cables.

Now we will affix the electrical cables to the circuit board, the three from the front forks will attach to the upper two sockets and the switch to the central left socket. The rear brake pedal will go into the socket on the middle right and the tail light just below it into the inner right bottom socket, the battery cable is attached to the inner left bottom socket.

This will leave the two rear indicator cables to fit, the picture indicates that the left cable will go to the right hand side socket and the other to the left socket but if fitted in this way it will result in the front right and rear left indicators flashing in unison when the switch on the handle bar is activated and the same for the other handlebar switch front left and rear right. To prevent this just put the left indicator cable into the left side socket of the circuit board and the right indicator cable into the right side socket. Once all the cables are in place put the circuit board just behind the battery box.

Next you will need the exhaust pipe from stage 52 fit the curved end into the rear cylinder head and then fix it to the frame using a 'V' type screw at the front hole and an 'I' type screw at the rear most hole. Next take the exhaust from stage 51 and its cover from stage 63, fit the cover onto the exhaust then place the curved end into the front cylinder head and fix onto the frame with a 'V' type screw.

Take the seat parts from stages 71 and 72 turn them over and clip the pillion seat into the back of the saddle seat then identify the three holes in the saddle bottom that will push onto the three pegs on the frame. Gently mount the saddle onto the three pegs making sure not to pinch the wires and that they run in a central line from rear to front.

Now take the fuel tank and remove the two filler caps, turn it over and fit the last electric cable from the speaker into its socket and mount the tank onto the frame lining it up with the two screw holes and fix it in position with two 'F' type screws and replace the filler caps. Next take the three cable ties from stage 13 and use two to gather the cables on each side of the handle bars the last one is used the tidy the cables from the front forks to the frame next to the fuel tank.


Your Fat Boy is now finished but there are still several extra parts to be fitted to the bike if you wish which will be fitted in the next part.

Take the backrest from stage 75 and fix the two side plates from stage 69 to it using two 'T' type screws. I next fitted the pillion backrest to the support [ stage 76 ] then added the two saddlebag mounts [Stages 67 and 70 ] using four 'G' type screws. Mount the backrest behind the pillion seat the saddlebag mounts will rest on the indicator brackets and then add both saddle bags to the mounts.

There are two fender plates from stages 47 and 58 fit one to the front fender and the other to the rear fender. Next clip the tail light cover from stage 69 in place and using an 'E' type screw fix the mudflap to the inside of the rear fender. If you wish you can remove the pillion seat and replace it with the fender bib from stage 73. There is also an alternative lens ring provided if you wish to use it just remove the old ring replace the lens into the new ring and refit. Stage 77 provided the windshield, attach the two clips but do not fully tighten the nuts on the screws then simply attach the lower two brackets to the forks and the upper brackets to the handlebars.

This completes the construction of the Harley Davidson Fat Boy, I hope you enjoy the build as much as I have!
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Current builds:-C57,Zero, Lamborghini Countach, Caldercraft HMS Agamemnon,Robi,R2-D2, MFH Cobra .

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