Designing the Front End

One of the most important parts to make sure is completely mechanically correct is the front end, specifically, the forks and triple tree.  Since I'm angling for a slick cafe bike with a scrambler twist, I really want to keep the front forks with the gaters (rubber boots).

The whole thing bolted together fairly easily, and I'm getting some great ideas about how I want to rebuild the lamp holders using the slick new aluminum ones.

My biggest problem with the front end is the crusty old sleeves.  They're dented, cracked and ugly.

The problem is that if I want to use the gaters, I have to utilize the lip on the bottom the sleeve.  However, I found my solution:

 

All I need to do is cut sleeve right above the little ear flaps that it uses to connect to the bottom of the triple tree.  That way, the new headlight ears can fit easily onto the forks and the front end keeps its' scrambler look, but also looks a bit more beefy and sleek.  Win-win.

I am, however, considering a second sleeve that covers the fork tube between the top of the new ears and the top of the triple tree.  At the very least, I think I'll add on a few spacers and possible paint the tube tops.  That's something to worry about later.  For now, here is today's parts order:

Order Qty Part No Description Condition Price Total 2 01-47-5065 WASHER,FORK OIL SEAL,RUBBER OR CORK (Priced As Each) (Customer Searched For Part Number 5065) New: $4.19 $8.38 2 01-47-5064 WASHER,FORK OIL SEAL RETAINING (Priced As Each) (Customer Searched For Part Number 5064) New: $0.93 $1.86 4 01-68-5056 BOLT,5/16CEIX26X1-1/8 ,H/BAR,CHROME (Priced As Each) (Customer Searched For Part Number 5056) : New Only $7.40 $29.60 4 01-15-5155 WASHER,21/64X33/64X.048,PLAIN (Priced As Each) (Customer Searched For Part Number 5155) New: $0.79 $3.16 1 01-68-5050I LOCK,STEERING,A50,A65,(INDIA) (Priced As Each) (Customer Searched For Part Number 68-5050) New: $22.46 $22.46 1 01-27-5135 BOLT,3/8CEIX26X1-9/16 ,CLIP,FORK TOP (Priced As Each) (Customer Searched For Part Number 5135) New: $15.53 $15.53 20 01-01-4675 BEARING,BALL,1/4 HUB LH,STEERING (Priced As Each) (Customer Searched For Part Number 4675) New: $0.33 $6.60 2 01-14-0303 NUT,3/8UNFX24,PLAIN (Priced As Each) (Customer Searched For Part Number 14-303) New: $1.22 $2.44 1 01-40-5090 CLIP,BRAKE CABLE GUIDE (Priced As Each) (Customer Searched For Part Number 40-5090) New: $4.40 $4.40 2 01-21-0785 BOLT,3/8UNFX24X2-7/16 (Priced As Each) (Customer Searched For Part Number 21-0785) New: $5.03 $10.06 1 01-64-6016 NUT,3/8CEIX26,SLEEVE TYPE (Priced As Each) (Customer Searched For Part Number 64-6016) New: $11.87 $11.87 Sub Total:    $116.36 Shipping Type:    FREE DOMESTIC OR DISCOUNTED SHIPPING Shipping:    $0.00 Tax:    $0.00 Total:    $116.36