Okay, here’s my take on the 1980 Harley FLT project, blog-style. Get ready for a long one, ’cause this was a beast!
Alright folks, buckle up! Today I’m gonna walk you through the resurrection of a 1980 Harley FLT. Found this beauty (or rather, beast) sitting in a barn, covered in more dust than paint. My kinda project!
The Initial Assessment: Oh Boy…
First thing’s first, gotta see what we’re dealing with. Dragged her outta the barn – man, was she heavy! The years hadn’t been kind. Paint was shot, chrome was rusted, tires were flat, and I swear I saw a family of mice relocate from the seat. But, the frame looked solid, and that Shovelhead V-twin… well, that’s where the potential lay.
- Engine: Definitely seized. Tried turning it over by hand… nope. Solid as a rock.
- Electrics: Forget about it. Wires were brittle, cracked, and chewed on. Likely gonna need a complete rewire.
- Bodywork: Dented fairing, cracked saddlebags, ripped seat. The usual for a bike this age.
Tearing it Down: Getting My Hands Dirty
Time to get intimate with this hog. Started stripping her down to the bare frame. Every bolt was a fight – rust was the enemy! Lots of WD-40 and patience (and a few choice words) were required. Labeling everything as I went, because, trust me, you think you’ll remember where everything goes, but you won’t.
The engine was the big challenge. Had to soak the cylinders in penetrating oil for days before I could even think about budging them. Eventually, with a little persuasion (and a bigger hammer), got it apart. Turns out, water had gotten in and caused some serious rust inside. Cylinders needed boring, new pistons, the whole shebang.
The Rebuild: Bringing Her Back to Life
This is where the fun began (and the money started flying). Sent the engine off to a local machine shop. They bored the cylinders, installed new pistons, re-ground the valves – the works. While they were at it, I cleaned and polished every single engine component. Shiny!
Frame got sandblasted and powder-coated. Decided to go with a classic black – can’t go wrong with black. Then, it was time to start reassembling. New wiring harness, new tires, rebuilt brakes – everything got replaced or rebuilt.
The bodywork was a bit of a challenge. The fairing had some serious cracks. Spent hours patching it up with fiberglass. Then, a new paint job. Stuck with the original color scheme, but with a modern clear coat for extra shine.
The Moment of Truth: Will She Start?
Finally, the day arrived. Bike was all back together, fluids topped off, battery charged. Turned the key… nothing. Checked the wiring, the fuel lines, everything. Turns out, I’d forgotten to connect the ground wire to the battery. Doh!
Connected the ground, held my breath, and hit the starter. Chug-a-chug-a-chug… VRRRROOOOOOM! She fired up! Sounded like a Harley should – loud, raw, and full of character. A huge grin spread across my face. All that work, all that sweat, all that money… totally worth it.
The Ride: Sweet Victory
Took her for a spin around the block. Felt amazing! The old girl rode like a dream. Still needs a little fine-tuning, but overall, she’s back and better than ever. Another classic saved from the scrap heap. That’s what it’s all about, right?
Lessons Learned:
- Patience is key. Don’t rush things.
- Label everything!
- Rust is the enemy.
- WD-40 is your friend.
- Don’t forget the ground wire!
So, that’s the story of my 1980 Harley FLT rebuild. Hope you enjoyed it! Now, if you’ll excuse me, I’m gonna go for another ride.
