[bigbreather]

I have a 2005 sportster 883 with the standard top mount headlight (under the visor) and want to change it to a bottom mount light like on the 883 Custom. On the Factory Custom there is a hole drilled thru the bottom triple tree to bolt the bottom mount to. Question: Does it seem safe to drill the same hole in my triple tree (5/16")? I really don't want to buy a whole new tree from Harley.Thanks

[chucktx]

if comparing the two trees, and the amount of metal is the same, you should be able to complete your project by carfully using a drill and tap....have fun!!

[kenfuzed]

I believe the trees are the same except for the underside drilling on the XL Custom model, so you should have no problem.

[bigbreather]

Howdy--

Thanks for the responses about the tripple trees--- it looked like a simple deal to me, so went and drilled out the lower. If it all goes to hell, breaks apart, and puts me into the long roll, well, that's my problem.

Work to ride, and ride to work.

[bikerjim1]

As long as you didn't tap the threads/ hole too deep into the tree, you shouldn't have any problems.

[FlynDutchman]

Originally Posted by bigbreather

I have a 2005 sportster 883 with the standard top mount headlight (under the visor) and want to change it to a bottom mount light like on the 883 Custom. On the Factory Custom there is a hole drilled thru the bottom triple tree to bolt the bottom mount to. Question: Does it seem safe to drill the same hole in my triple tree (5/16")? I really don't want to buy a whole new tree from Harley.Thanks

I have a Superglide, which has basically the same front as your bike & I've been thinking about doing the same thing....I hate that flippin visor & want to get a billet headlamp but what do you do about the holes that were there for the visor ? just leave em ?

Steveo

[FlynDutchman]

Originally Posted by bigbreather

Howdy--

Thanks for the responses about the tripple trees--- it looked like a simple deal to me, so went and drilled out the lower. If it all goes to hell, breaks apart, and puts me into the long roll, well, that's my problem.

Work to ride, and ride to work.

After I responded to your original post I went out & looked at my trees, there seems to be alot of metal to drill through since the metal in the center on the underside isnt cut away like the rest of the tree....(I'm guessing for strength) I'd like to know how that worked out for ya since Im none to hip on throwing out a couple grand for a new front end

[bigbreather]

Thanks for all the thoughts. Here is what I know--- had to buy a right angle drill from Harbor Freight to get into the lower tree (fender had to be removed), but it was only $30.00--- I figured that was a lot cheaper than pulling the front wheel assembly, which required lifting the front end, removing the wheel/brake/fender/and then setting it all back up again with a dial indicator (according to the HD manual). Started with a 1/8" pilot hole, then bored it out for clearence for the mounting bolt. Countersunk the bottom so the washers would work, and replaced the hex bolt with an Allen cap bolt fitted to a convex spacer to fit within the casting (ground the spacer). So there it is-- a low mount headlight that cost $52.00. As far as cleaning up the top mount, I bought the stock stamped metal/chromed trim from HD for the Custom Sportster-- bolts right on to the stock top light mount, very clean, and hides the wires. That was $45.00. So I have about $130 in this new look, but I like it.

[chucktx]

that is great. thanks for sharing you modification...im sure it will help others here. if you can post a pic that would be a plus!!!!
chuck

[FlynDutchman]

Originally Posted by bigbreather

Thanks for all the thoughts. Here is what I know--- had to buy a right angle drill from Harbor Freight to get into the lower tree (fender had to be removed), but it was only $30.00--- I figured that was a lot cheaper than pulling the front wheel assembly, which required lifting the front end, removing the wheel/brake/fender/and then setting it all back up again with a dial indicator (according to the HD manual). Started with a 1/8" pilot hole, then bored it out for clearence for the mounting bolt. Countersunk the bottom so the washers would work, and replaced the hex bolt with an Allen cap bolt fitted to a convex spacer to fit within the casting (ground the spacer). So there it is-- a low mount headlight that cost $52.00. As far as cleaning up the top mount, I bought the stock stamped metal/chromed trim from HD for the Custom Sportster-- bolts right on to the stock top light mount, very clean, and hides the wires. That was $45.00. So I have about $130 in this new look, but I like it.

Any way to see Pictures ?

[bigbreather]

Hey, and again, thanks for all the great responses. Finally talked to a mechanical engineer ( about the hole in the fork)-- he said, "why did you ever give it a thought".?

Anyway, done is done. Take a Look. Boys, if you have any questions, please let loose.

[kenfuzed]

Looks great!

One question, can you see the speedo past the risers/clamp or do you just use the seat of your pants?

[voodoochild]

who needs a stinkin speedo anyway!? long as you ain't gettin pulled over, what's the difference?

[FlynDutchman]

Looks good man....you've inspired me to get rid of that brow on my Dyna.....I may have to hit you up for some technical expertise though !!

[bigbreather]

A little more about this front end--- the risers are 4.5" (as far as the stock front brake hydraulic line will allow), and I am 5'8". When I look at the speedo, I see it fine right over the top clamp. I don't see 10 mph or 120mph at a glance, but neither of those speeds mean that much to me. Ican see the nuetral light and turn signals if I want to by bobbing my head around, but I never had them in the old days, and don't really care. Oh yeah, something else about that HD trim piece for the top tree---it really hides everything, but I had to cut out the center on a milling machine to low mount the speedo. Too many wires. After I took the center out, I wrapped the edges with 1/4" irrigation hose (split) to protect the wires. I think the last pic might show that

[chucktx]

very nice job, thanks for sharing the tech and pics!!