Blood, sweat, tears & beers . . .

I've already attached the two planks together with 2x4's, but will take your advise and use oversized dowels so I can take them apart. I think for now the ramp will work to get the bike off the truck.
I'm going with the idea to have sleeves welded into the holes in the frame. I'll have to pull the front pulley off because I think the belt would be in the way of the welder, (see pic) which means I'll have to buy a puller. Always something. Also have to tear the rear wheel & brake off to get a stupid washer in between them (see pic how close the bolt head is to the brake bracket - funny I never noticed it before. The clearance is .017"). All this sets me back again, but I'd rather not ride with a compromised frame. Mark it all up to another botched job by yers truly. S**t!

not botched untill it hurts something, just needs a little tweaking...

When I drilled those holes, (the first one 2 years ago when I first got the roller) I thought that a tight fitting bolt would keep the frame from flexing at that point - almost like no holes at all. Works with wood so I thought it would work with metal. Both of those bolts were pretty snug - had to tap them back thru the holes a bit to get them out yesterday.
I drove the bike back to town before we off loaded it and had the welder take a look at the holes. Good news is that the welder said he would be able to weld around the belt. he will mask it off with something they have in the shop just to make sure nothing happens to it. I would have had the holes taken care of right then, but I didn't have the sleeves made up yet. Maybe by the end of the week . . .

Turns out a washer for a spacer between the wheel and brake bracket won't work - it will bind the brake against the rotor. So I'll try using button head bolts instead of the hex head ones I now have. The button heads will give me the extra clearance I need, and I think I'll be able to access everything without taking the wheel off. WHEEE-DOGIES!!

Yes, it'll give me a total of .062" - around a 1/16". That's a lot better than the 1/64" it is now. It's either that or take the brake off and grind relief slots in the brake bracket. I don't want to do that. I believe the 1/16" will be enough clearance.
Going to exchange one of my banjo bolts today for a different angle & also get the five allen bolts for the rotor.
I've made a solid plug for one of the holes in the frame. (See pic). Once that's welded in, I'll have the new bracket I made welded in just behind it. The new bracket looks exactly like the brackets I made for the exhaust pipes & will hold the brake switch.
The other hole (on the other side of the frame) will have a sleeve welded in so I can run a 1/4" bolt through it and attach the custom bumper I made. (See other pic). It sticks out farther than any stock bumpers to clear the belt more. These pieces are so small and yet so critical!
BTW, the exhaust brackets fit perfectly - I mocked up the pipes last night to make sure.

While in Tarboro today, I will attempt to get the insurance and N.C. title/plate for my bike. Hope all goes smoothly . . .

I got the title & plate. So cool. Then I went and got the insurance, too. I still can't believe it, but it went without a hitch. Next is the inspection . . .

Today I got 5 stainless bolts, nuts & lockwashers for the rotor. The allen bolts I got from the Harley dealer were even thicker than the ones I have, so I'm not going to use them. I'm grinding some material from the heads on the stainless bolts - one is installed (see pic). The pic on the left is the clearance I had with the old bolts & the pic on the right shows the clearance with the stainless bolts. Much better!
One down, four more to go . . .

Ha-ha! Yeah, but I know I can't fool myself! I'm going to have to wait until the end of next week til I can get the last of the welding done which means I can't put the exhaust on to try and start it now because once the exhaust gaskets are mashed and you take them back off you have to put new one's on. I don't have an extra set.
Anyway, the new license plate is on. I'm legal to ride right now, but I have to wait because I made the mistake of drilling holes in the frame.
In the first pic it shows where the slug will be welded into the hole. Next pic shows the bracket I made that gets welded to the inside of the frame (in the same location) to hold the brake tee.
Next pic shows the bolt that gets welded to the frame so my custom bumper can be attached to it. After that, I should be ready to roll . . .

Are you using those crappy crush type gaskets that HD uses all the time? If so, ditch those and get different ones.

Those would be the ones.....

Screamin' Eagle gaskets? I'd have to drive 60 miles round trip to get 'em. Guess I'll have to suck it up if they're that good. But I wonder if they'll fit the shovel pipes. The ones I have are crush gaskets. I thought they were all right . . .
Yeah, I used locktite on the rotor bolts plus lockwashers. Couldn't get a torque wrench on them, but they are tighter than Dick's Hatband.