Very cool. Can’t wait to learn more about your build

 

Great plan but I do love the anniversary bikes as is. After seeing the 23 CVO's the older bikes are just "classic"...I do dig the Italian neighbor of your bike in your garage!

 

I really like the Rushmore look, and there were SO many anniversary bikes made, I didn't think anyone would miss one with what Im doing. Honestly, it took a while to even figure out the direction I took - 20 years later, and every aftermarket part is geared towards newer stuff - if you go pre-2009, you have to dig deep to find stuff that will fit. I wanted to keep the tins to sell the set, and not a single new old stock tank in the market. Had to find a good used one. Thats just one example, but there are others.

I agree on the 23 CVOs - tech marvel, but they are really starting to look a lot more like the Japanese Touring bikes to me! That blue thing in the background is British! Straight from Surrey England.

 

I really need to study up on my supercars, she's a beauty!

 

Looks neat love it

snaptube vidmate​

 

damn. screw the bike lol
i couldn't afford the maintenance on that sweetheart

 

Simply amazingly…..wow…


Sent from my iPhone using Tapatalk

 

Can't wait to see how it turns out. Appears to be a great build.

 

If you plan to let go of your current headunit I sure would be interested

Awesome project man, can't wait to see the finished product!

 

PM me - Im selling it for sure. It's still under warranty which I confirmed is transferable. I bought it in May this year before I decided to jump in the direction I have ultimately gone. Reasonable offer and its yours!

 

Front end swap is underway - kit is noted above in the list from Geezer Engineering. Couple of things to say up front.

First the support from that team is top notch. I send a question in email and they respond within 30min! Second, the quality is great - parts are designed well and show a great deal of care, from the packaging, to design, to the install...flawless.

Moving from a 41" to 49" has a lot of thought put into it.

The triple trees have rake built into them, but for OEM like end results. The geometry would not work without it out due to the fact that the fork legs are behind the neck. It is the same rake as the 2003 trees have but they built them with a slightly different offset to optimize the geometry.

I purchased the 22-7/8” tubes and matching cartridges. While the tubes are longer than the old tubes the bike will retain stock ride height. This is because the 2003 trees are dropped down a bit and the fork caps protrude into the top tree as opposed to the fork tubes being clamped down on.

The net net is that this all sits like a stock ride, but as you are fitting it, the set up looks like you are building out a front end for a 23" rim - something to note if anyone else goes down this path.

 

Old wheels back on so it can roll around. Powder coated parts should be back to the shop Friday!

This is the 49 set up from Geezer now on the bike with the 2014+ lowers. From here, it's all about building it back up. Pretty cool! PS - not me in the background! lol

 

Hey everyone - new to this forum, but have been finding myself using it for a lot of helpful information.

I have an 03 Anniversary Road Glide that I decided to do some changes with...at first I was doing it myself and keeping it largely simple. I added an LED update, fairing drop kit, and a Soundstream radio unit. It was all good stuff but I kept eyeballing the new versions of the RG and it kept nagging me to consider more.

After looking at new prices and well sorted used stuff, I decided to keep what I had and have it updated with a lot of the new look that I like...so, here I am doing that!

First off - hey! This is my first post but over the last few months every search where I was stuck always lead me back here and I walked away learning something new. This thread is an example and a great write up - thanks for it; gives me hope for what I am already heavily invested in!

Like I said, it started as a simple 'refresh' but it has turned into what I would say is more of a restomod. I'm going through the entire bike and doing updates. I am doing:

• Rushmore conversion (keeping the same gauges though - no CANBUS update)
• 180 18" wheel update
• 41mm to 49mm front fork conversion
• tune, cams, true duals, modern bags, tour pack etc etc etc.

Small list in bullet form above but...wow, the parts add up! Lots of people have been asking in threads how to put it all together, and honestly as extensive as the list is below, its incomplete in the notion that I know to complete it fully, there are surprises hiding around the corner. That said, along the way I have found some pretty cool options to consider as you migrate from old to new. Here is a list of the things I found and am incorporating into the build to get the results I want:

Geezer Engineering:
fork conversion: Triple-Tree, Fork-Slider, 49mm Tubes, Cartridges 2013 Touring & prev.
* this will take your 2013 and earlier, brake and fender but if you want to update to Bremos and the 2014+ fender the stock lowers will plug and play too*
2014+ cowbells: Amazon.com
brake/tail light: https://www.amazon.com/dp/B09V7NMFFP?ref=ppx_yo2ov_dt_b_product_details&th=1
plate frame: https://www.amazon.com/dp/B07QR5YMFW?ref=ppx_yo2ov_dt_b_product_details&th=1
180mm wheel/tire convert: Wide Carbon Fiber Fender for 2008 & earlier Harley Touring Models
easily the cleanest update out there!

Note Cycles:
radio update: https://notecycles.com/collections/...stream-reserve-harley-davidson-head-unit-2014
radio bracket: Amazon.com

Rushmore conversion:
fairing kit: Amazon.com
painted glove box covers: Vivid Black Inner Fairing Glove Box Door Cover Fit For Harley Road Glide 2015-23 | eBay
upper air duct (painted with mech): Vivid Black Top Air Duct Piece Cover Fairing for Harley Touring Road Glide 15-UP | eBay
inner fairing brace: https://www.amazon.com/dp/B01LY5NBB5?psc=1&ref=ppx_yo2ov_dt_b_product_details
fasteners: https://or422464.ari-final.com/cart...fa3845/1e10307f-42bf-4d8b-ad7d-85ed5f42e678/y
windshield: https://www.amazon.com/dp/B01JUKN6BU?psc=1&ref=ppx_yo2ov_dt_b_product_details
headlights: Amazon.com
tour pack: Amazon.com
2014+ bags: https://www.amazon.com/dp/B085TDC8CD?ref=ppx_yo2ov_dt_b_product_details&th=1
S&S True Duals: https://www.sscycle.com/products/power-tunereg-dual-headers-for-19952008-touring-modelsblack/
S&S Slip Ons: https://www.sscycle.com/products/mk...k45-touring-muffler-for-19952016-touring-modelsblack-with-black-tracer-end-cap/

These are the basics for everything I'm doing...there is more depending on how deep you make your updates and also its much smaller if you just wanted to do the Rushmore conversion only...I went deeper. Also I was lucky enough to get a 3D printed mod for the gauges to fit the new fairing.

I'm not doing this myself - its a puzzle that I'm leaving to my builder, Jim at Metal Dragon in Hayward CA. It's the third project I have dropped on his doorstep and I gotta say, the guy is a perfectionist in the best way possible. Ready to wade into the unknown, and has always solved any challenges with OEM quality and safety when its complete.

Ill continue to share what I learn along the way!

View attachment 465975 View attachment 465976 View attachment 465977 View attachment 465978 View attachment 465979 View attachment 465980

I got the same bike, but black.
I started in the other end.
bringing together parts now, to do conversion this coming winter.

A S&S Sidewinder 100" kit
Feuling hydr cam tentioner kit w high flow Feuling oil pump
Feuling 525 cam set
Ultima 6 speed gearbox
18" front wheel w 14" discs and 2020 Bremos, and 2020 master of course.
Ported heads w bigger valves/springs.
Fat Boy inspired front fender.

After that the bike will still look mostly std, but will behave totally different.

Nex winter I’ll do the exterior bit.

I like what you’re in prosess of doing and I have saved your post for later study.

 

I got the same bike, but black.
I started in the other end.
bringing together parts now, to do conversion this coming winter.

A S&S Sidewinder 100" kit
Feuling hydr cam tentioner kit w high flow Feuling oil pump
Feuling 525 cam set
Ultima 6 speed gearbox
18" front wheel w 14" discs and 2020 Bremos, and 2020 master of course.
Ported heads w bigger valves/springs.
Fat Boy inspired front fender.

After that the bike will still look mostly std, but will behave totally different.

Nex winter I’ll do the exterior bit.

I like what you’re in process of doing and I have saved your post for later study.

Just putting the finishing touches together and saw that you updated the master cylinder along with brakes.

Did you update the rear master as well? Its completely different after 2007 - wondering because it would require 2008 foot controls on the brake side. This actually makes it a lot easier to update foot controls. If you did it, could you explain how you did it and provide some photos?

 

powder coating is back now. Looks good...and thats the trigger to start putting things together. Paint on the tank replacement and the front fender will come back next week but lots to do before they become necessary yet anyway. Added a 2-part rear brake system too. Being able to remove and install the 18" 180mm tire was like getting your high school date out of her prom dress, so being able to remove the caliper first will make things a lot easier going forward.

As for the Prodigy front wheel and the rear not matching...cush drive.

 

OK. Progress continues! Jim runs a very busy shop over at Metal Dragon, but he put some time aside today to make progress and it was great timing to drop by!

First, here's a partial look at some of the powder coating that was done. Lots of reworking there, and the pics do a tough job of the quality. There were a couple of parts that had gassing issues, but they were areas that would be highly exposed. The parts that needed to be perfect were - so that success!

Second was getting the lighting done - I wanted something that would be OEM like but of course not. I went with the brake/signal 2 light combo and since the fender didnt have mounting service areas like a factory fender, they had to be cut to the fender shape and then reinforced from the back so it doesnt risk cracking the fender. Done!

Last, was fitting of the rear wheel and new rear brake assembly.

The set up is down to the millimeter for clearance, so the stock brake doesn't work well. To remount the wheel you have to leave the disc brake loose on the hub making it next to impossible to thread the wheel and the brake and the caliper etc for mount/dismount, so the 2 piece system is there going forward.

Shims were perfect on the wheel set up but the belt pulley needs a shim (just under an 1/8" to align the front and rear and prevent it walking out to the edge. Overall this is it - 18" 180mm wheel inside the fender from Geezer working absolutely flawlessly. Shims and locktight and onto to the next head scratcher (there are several before this thing is finished!)

 

Bikes looking good bro!

 

I'm not doing this myself - its a puzzle that I'm leaving to my builder, Jim at Metal Dragon in Hayward CA. It's the third project I have dropped on his doorstep and I gotta say, the guy is a perfectionist in the best way possible. Ready to wade into the unknown, and has always solved any challenges with OEM quality and safety when its complete.

this is the first i saw this thread, looks like a very involved project that should yield some good rewards.

i just wanted to say that metal dragon are good folks. i bought my legends shocks and axeos from him. for a very good price too. offers discounts on corbin seating as well. like to see his shop get more exposure.

 

I would add, incredibly talented. I met him in 2008; pretty random. I had just purchased an new new SE Ultra and had him put a fat tire kit on it. His work was great so back I came a couple of years later with a full project. What started as a factory softail needing a lot of work, turned into a fully custom bike that you could drive for a hundred miles without a sore back! It won some show prizes and a feature in a magazine. I sold it at a low point, and now Im back for more and he's really my only choice. The nice part of Jim's approach is he's not a 'builder' but will take on these projects and make them bulletproof.

Found a couple of pics that tie this all together. The first is the custom bike beside the one he's currently working on (my friend had owned it previously). The second is a better look of the custom bike he built me.

 

OK more updates! Once again thanks to Jim for diving into the unknown!

First, back end is all lock tightened and the custom back brake is in - again there is ZERO clearance in the back wheel set up, so having this 2-piece brake set up was a must to make the wheel removable and mountable without a full day of swearing!

next came the fender wings. They look simple enough, but there isnt enough clearance for a screw or bolt head on the inner fender to mount these. So it took a headless screw set up mounted (welded) on a plate so that the tire would clear it. Mission accomplished - again, some of the creativity out of Jim at Metal that I have learned to expect. Here is the final look:

Front wheel went on today too - complete OEM swap over with 2020 Prodigy wheel. Since the lowers are 2014+ its OEM spacers and brake discs. Also swapped over to Brembos from a newer bike.

So, back is complete and front wheel and forks, now on to the fairing update. The new bracket is on Im going with a Paul Yaffe drop kit and hidden fairing brace. Unfortunately hit a snag - the lowering bracket needs the tabs cut from the stock fairing bracket, but when this was shipped to me, it didnt come with the new tabs on the lowering bracket (they are screw mounted). So, more to come, but for now stopping here:

 

Time for that annual inspection too! Don't let that tag expire.

OK more updates! Once again thanks to Jim for diving into the unknown!

 

Gettin there……..

 

Slowly but surely. This is one helluva build! I appreciate you for sharing it.

 

No "cool guy" remote reservoirs!?

You'll have to share the labor total after this is all said and done. Awesome build!

 

I had to think a little about what you meant by that....nope. Too funny - I guess Im not cool enough (and didnt want to spend double for my Legends!)!

The carbon fender maybe compensates a little bit but it'll blend well with the Vivid Black.

 

more updates...cant crack the casings without doing a little engine work! it had all of the 95" work done before it rolled out of the HD Dealership but, it was the HD kit. So S&S cams and an updated cam chain tensioner.

 

Great build! Can’t wait to see finished product.

 

Cams are back in and this side of the engine is sealed. A lot of the black powdercoating is starting to come together now. Primary side is getting sealed up and then the S&S True Duals and Exhaust are going on. This thing is starting to look like a bike again. Cant say enough about Jim and his work. Nice to be able to document it all and share here too - thanks for the feedback from everyone and the place to share!

Gotta say it out loud...this is one of the best forums I've been on - 99.5% of the comments are constructive...haven't seen any trolling - very cool group of people!

 

This is gonna be a bad motor scooter………!

 

The updates are coming in fast. This has been a week leaping forward.

The engine is all put back together and the exhaust went on. Everything is tying together well and no issues. Havent been able to start it yet - the painter keeps dragging on his timing promises. FIngers crossed that the tank and front fender are delivered all done next week.

OK so the fairing on this last photo is a test fit. I have the 2014+ fairing bracket on the front and combined with the pre-Rushmore gauge cluster and there is no clearance for turning. I used a Paul Yaffe 1.75" drop kit along with a hidden brace.

The kit pushes the fairing forward about 3/8" but not nearly enough. If you are going to do this swap, you need to plan to move the mounting point for the inner fairing out about 1.25", Jim will be building a custom fairing bracket with the test fitting measurements he landed on, but there really isn't anything out there available to get this to work.

Keep in mind, Im using pre-CANBUS gauges and modified triple trees so using the new gauges or even the new gauge housing wasnt an option. In the end the fairing ends up where I would want it anyway. Those that are thinking about doing this though - save some time to figure this out before you start! Here is the final place the faring will sit once the new bracket is fabricated. Its perfect - more pics when the tank comes so you have a better frame of reference, but this lower setting makes it look super aggressive, yet still OEM.

Hope this helps others!

 

Love the fairing adjustment.

I also have prodigy wheels on my build list. Figure I’ll basically build a 49mm front end on the side in the garage and bolt it up when finished

 

The Geezer Engineering 49mm tree and fork set up I have is REALLY well engineered. You might want to check it out. It's a little pricey for sure, but it includes everything you need including all the engineering work they did.

fork conversion: Triple-Tree, Fork-Slider, 49mm Tubes, Cartridges 2013 Touring & prev.

It looks like a simple tree swap but there is a lot more involved. The triple trees actually have a rake built into them - when they are first mounted it looks about the same fit as when someone is trying to fit a 23" front wheel! Geezer figured out that the geometry would not work on the earlier frame set up without it due to the fact that the fork legs are behind the neck. Once it is all put together, you can see by the photos that it's the same rake as the original trees have but they created a slightly different offset to optimize the geometry.

Even the fork tubes need to be rethought. I received 22-7/8” tubes and matching cartridges. The tubes are longer than the pre-2014 tubes that my '03 RG bike came with but it compensates for the set up and retains stock ride height. This is because the old trees are dropped down a bit and the fork caps protrude into the top tree as opposed to the fork tubes being clamped down on.

Hope that makes sense and maybe saves some head scratching in the future.

 

so, complete refabrication of the fairing bracket. Jim essentially test fitted the spot (previous photos) engineered a way to weld new mounting extensions and get back to the exact spot for the final fit with clearance for the pre-rushmore gauge cluster. Check that box...tins arrived too. The aftermarket dash is trash though, so now that is being rethought. Its looking more and more like a bike now though...

 

Great progress - going to be a badass bike!