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[Puzzled]

The hole was drilled to accept a "nut-sert". We had considered tapping the frame but wasn't to sure as to the strength of just a few threads. An alternative was to drill and weld a slug in and tap it. We figured we would go that route if the nut-sert doesn't work as we would like it.

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Next time I'll buy a bigger insert tool as this one takes a bit of pressure to get it to clamp tight.

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One detachable tour pack bracket.

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After removing the tour pack from its original brackets we fitted it to the new bracket. Since we moved the detachable bracket back this obviously moved the tour pack back. Our concern was when the owners girl was in the saddle she would be so far back as to have a hard time reaching over the crash bars to gain access to the floor boards. We decided to shorten the bracket thus allowing the tour pack to come forward. We added about 1 1/2" to the original distance as this seems to be what the aftermarket setups are doing. This is a shot of cleaning up the cut line from the cut off wheel. (Time for a new sanding disc! )

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Here we are attaching the bracket to the tour pack. I found it odd that the original tour pack mounted using the indented area intended for tubing. Whereas the new one mounts flat against the glass. At first I thought this may not be strong enough. After looking closely at the tour pack there are indented holes which match our holes in the bracket. Add the fact that there is a hefty piece of metal inside of the tour pack and we should be good to go.

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A shot of the tour pack mounted with the bags on. We appear to have the brackets and detachable stuff all figured out now. Next is the mounting of the license plate and than the fender can head off to paint.

We have a set of filler strips here for the bags but for the life of me I can't see how the go on. Anyway you place them they look like crap. OEM fillers would work however they would be a little narrow. I think I'm going to bend up a set of fillers as opposed to trying to adapt anything. This way they can head to paint also.

The swing arm made it back from BB this past week. The bushings have been pressed in and it is ready to go on the bike. The wheel is suppose to ship on the 1st which will allow us to wrap up the rear of the bike relatively soon.

The license plate has changed several times already. There will be enough parts here to figure out something. As of NOW we will be using the Russ Wernimont plate with integrated signals. I picked up the optional bracket to mount it on this fender. The owner would like more visible signals as opposed to the integrated ones (I agree) so we will have to incorporate them.

We should have the new crash bars this week without the holes in them for the extra bag bars. About the only thing that hasn't been ordered yet is a set of slip ons. The owner is still scouring E-bay for a set!

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Another evening was spent working on the Bagger. Not much was accomplished visually but it was stuff that had to get done. The swing arm is now back on awaiting the wheel. That was a little bit of a challenge having never put one on before. Nothing like a Softail swing arm. It just sort of floats in there in those bushings, weird.

The shocks are now back on. They lost a little bit of oil out of the air valve so I'll need to do some research to see what type of oil should be in them. The HD manual says they are non serviceable however if oil came out it should go back in!

We increased the size of the docking hardware from 5/16" to 3/8" just because it looked like it was bending the smaller bolt. Maybe it wasn't but a bolt change is pretty cheap.

The exhaust crack was fixed and all of the heat shields are back on now sitting loosely.

The fender needed a few more holes which is now done. Some of which were for the license plate bracket.

We made a template for the bag fillers and I'll try to make the real deal sometime this week. We're hoping to get the bare metal parts to the body shop in the next few days. I suggested doing it here but the body shop guy owes the owner of the bike so they are working that out between them.

There really isn't a lot more to go at this point. A detachable antenna mount needs to be made as well as a plug to make the tour pack harness removable.

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We replaced the bushings due to boggering one up trying to get it out of the arm. So now it has new bushings. On that note I came across those Sta-Bo bushings which I think I'm going to try in my own bike. That may stop my mystery squeak. Your right on the alignment. We had to loosen the front lower mount in order to get the rear bushings to sit square. Time consuming.

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Here you can see the areas that had to be ground down in order to fit the fender. The bracket just above the belt had to be cut back some also. Pretty much anything inside of the rails had to go.

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The left side of the new wider arm.

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On the previously posted picture of the front lower mount you can see how the mount is running back some. This was just enough to not allow the swing arm to go in.

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Well it's been a week or so and it seems as nothing has progressed on the bike. However the parts are coming in. The wheel arrived and looks really good for a polished wheel. The owner picked up a set of V&H's from HDwebtrader and they shipped already. The Lyndel brake pads came in also. We're waiting on the wheel spacers and the paint that was suppose to be here this past weekend .

The owner had me order up the chrome 21" x 3.5" front wheel with matching polished rotors and Metzler tire. RC Components says I should see it in about two weeks. That means we'll have to come up with chrome lowers and figure out what to do with the cow bells. I think they look good painted as it breaks up some of the chrome.

Our fender score turned out to be a piece of... well that's not fair to say as it was free! It's just not worth the time to work on it. It was suppose to only be scuffed however it is twisted and creased. We can do better with a different one. I've been checking out the custom baggers and sort of like the chrome rear trim on the front fender.

We need to score a few OEM HD parts and that should sum up everything, I think.....

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Making the bag filler strips. First out of cardboard than out of stainless.

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Checking them before we have them painted.

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Painting the ground down areas with POR.