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Build-Off - Street Chopper Editor

Part 17: Prepping A Chopped Sportster Motor For Polishing And Revolution's Millennium 1,250cc Big-Bore Cylinders
By Greg Friend
Photography by Greg Friend
Strong
Last issue I had the rear... 
   
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Strong
Last issue I had the rear mount welded to the rear section of the chopped Sporty cases. While Mike (an employee at Orange County Welding) was welding, I told him to make the welds strong instead of pretty.
Start
I started to make the cases... 
   
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Start
I started to make the cases pretty with a porting bit and a hand-held drill.
Angles
A different-shaped bit was... 
   
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Angles
A different-shaped bit was used to get at the assorted angles of the cases.
Grind
With an angle grinder I removed... 
   
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Grind
With an angle grinder I removed some of the large, rough edges created by the initial cutting of the cases.
Porter
A rasped porting bit removes... 
   
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Porter
A rasped porting bit removes material at a slower rate than the grinder or the bladed porting tool. It's also easier to control when precise material removal is necessary.
Ninety
Cleaning up right-angle welds... 
   
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Ninety
Cleaning up right-angle welds requires a special tool. HTP America built a belt sander specially designed for this use, and it works great.
Cleaner
A few hours of work, and I... 
   
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Cleaner
A few hours of work, and I had a motor that no longer appeared chopped-and possibly as if it had never been modified at all.
Elbow
Finally, I used good ol' sandpaper... 
   
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Elbow
Finally, I used good ol' sandpaper and elbow grease to finish it.
Cover
With all the aluminum removed... 
   
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Cover
With all the aluminum removed from the cases, the cam cover didn't look as if it fit anymore, so I had to modify it as well. The red marks on the surface show the first two design ideas I had, but when I was about to start cutting, I changed my mind again.
Gasket
Here I am pointing to the... 
   
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Gasket
Here I am pointing to the new lines of the cam cover: the border of the gasket surface. The metal surrounding the gasket surface is merely to cover up the oil pump with edges that line up with another cover for the final drive.
Sawzall
Once again, the Sawzall made... 
   
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Sawzall
Once again, the Sawzall made quick work of the cam cover.
Tamed
The sharp edges were tamed... 
   
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Tamed
The sharp edges were tamed with the angle grinder and further smoothed with the flap wheel sander.
Extra
A large portion of the cover... 
   
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Extra
A large portion of the cover is strictly decoration.
Ready
And the finished cover, ready... 
   
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Ready
And the finished cover, ready for polishing.
Mock
I mocked up the motor for... 
   
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Mock
I mocked up the motor for a few teaser pictures of how the motor looked before it was polished, with the original cylinders.
Revolution
Revolution's Millennium cylinders... 
   
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Revolution
Revolution's Millennium cylinders are aerospace bred, and the perfect fit for the build. These cylinders are bored to 1,250cc and are cast aluminum with a nickel-based cylinder-wall coating instead of the usual iron sleeve. The first major advantage of all aluminum is its ability to hold in less heat, as aluminum cools far more quickly than steel.
Six
Also, Revolution's cylinders... 
   
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Six
Also, Revolution's cylinders weigh less than stock cylinders; this stock piece weighs almost 11 pounds.
Eleven
The Revolution Millennium... 
   
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Eleven
The Revolution Millennium cylinder weighs just over 6 pounds.
Smaller
The stock cylinders measure... 
   
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Smaller
The stock cylinders measure in almost a half-inch smaller than the 76-cubic-inch total of the Revolution Performance Millennium cylinders.

Toyota Tundra Research
Toyota Tundra Get all the information you need on the new Toyota Tundra. The Tundra comes with a V6 standard engine and goes for a suggested retail price of $28,405.00. It also has drivers side crash test ratings of 4 stars and passengers side crash test ratings of 4 stars. You also might want to research the Dodge Durango and the GMC Sierra.

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