Alright, buckle up folks, because I’m about to spill the beans on this ’78 Harley project I just wrapped up. It was a wild ride, let me tell you.
The Beginning – Finding the Beast
So, it all started when I stumbled across this ’78 Harley-Davidson Shovelhead sitting in a buddy’s garage. Covered in dust, hadn’t run in years. Classic story, right? But there was something about it, that raw, untamed look, that just screamed “rescue me!” I knew I had to have it.
After some haggling (and a promise to help him clean out his garage – deal!), I hauled the beast home. First thing’s first, I gave it a good scrub. Years of grime just washed away, revealing some pretty decent bones underneath.
Tearing it Down – Getting Intimate
Next step? Total teardown. I’m talking every nut, every bolt, every wire. I wanted to see exactly what I was dealing with. Took a ton of pictures along the way – trust me, you’ll thank yourself later when you’re trying to put it all back together. Bagged and labeled everything meticulously. Organization is key, people!
The Engine – Heart Transplant Time
The engine was the big question mark. I pulled it apart, and yeah, it wasn’t pretty. Gaskets were shot, cylinders were scored, you name it. I decided to go for a full rebuild. Sent the cases and heads to a local machine shop to get them cleaned up and inspected. New pistons, rings, valves, the whole shebang. Basically rebuilt the heart of this old girl. Honesty, I spent more time on this engine than I care to admit,but she needed it.
Frame and Body – Stripping Down and Building Up
While the engine was out, I turned my attention to the frame and bodywork. The frame had some rust spots, so I stripped it down to bare metal, welded in some reinforcements (nothing crazy, just some extra support), and gave it a fresh coat of paint. I went with a classic black, because you just can’t go wrong with it.
The original fenders were dented and rusty, so I decided to go with some aftermarket bobber fenders. Chopped ‘em, shaped ‘em, and painted ‘em to match the frame. I swapped out the old, clunky seat for a low-profile solo seat. Comfort is overrated, right? (Okay, maybe a little bit of comfort.)
Electrical Nightmare – Wiring Woes
Okay, let’s talk about the electrical system. It was a mess. Wires were frayed, connections were corroded, and the wiring diagram looked like it was drawn by a toddler. I decided to just rip it all out and start from scratch. New wiring harness, new switches, new everything. This was probably the most frustrating part of the whole project, but I persevered, and eventually, I got it all wired up correctly. I even added some modern touches like LED lighting and a digital speedometer,trying to keep the old soul, but with some modern upgrades.
Putting it Back Together – The Moment of Truth
With the engine rebuilt, the frame painted, and the electrical system sorted, it was time to put it all back together. This was where all those pictures and labeled bags came in handy. It was like a giant jigsaw puzzle, but with greasy parts and the occasional swear word. Slowly but surely, the ’78 Harley started to take shape again.
First Start – Sweet Music
Finally, the moment of truth. Fresh oil, fresh gas, and a prayer to the Harley gods. I hit the starter button, and after a few cranks, she roared to life. That sound… that glorious, rumbling, earth-shaking sound… it was music to my ears. All that hard work, all those hours spent in the garage, it was all worth it.
The Finished Product – Rolling Thunder
After a few test rides and some minor adjustments, the ’78 Harley was finally ready to roll. It’s not perfect, by any means. It’s got some scratches, some dings, and a whole lot of character. But it’s mine. And it’s a testament to the fact that with enough patience, perseverance, and a whole lot of elbow grease, you can bring anything back to life.
So there you have it, folks. My ’78 Harley project from start to finish. It was a labor of love, a challenge, and an adventure. And I wouldn’t trade it for the world. Now, if you’ll excuse me, I’m going for a ride.
- Cleaned and inspected everything.
- Rebuilt the engine with new parts.
- Repainted the frame and bodywork.
- Rewired the entire electrical system.