Aftermarket Breather Cover
Installation
Bracket How-to for the LC Intruder Conversion
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While the LC Intruder's massive "Chromed Cough
Drop" Pair valve cover has a unique character all
its own, many owners prefer the look of some of the
aftermarket air breather covers offered for the H-D and
Vulcan bikes.
After removing the Pair valve system from the bike, a new
bracket will be required for installation of the new
cover to the cylinder walls.
Our friend "Crow" has agreed to share his
method of attaching one of these fine covers to the LC.
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Parts
needed:
Round cover of your choice;
"I used the 'Inferno Cover" from
J&P Cycles, part #27-641" (any 8"
cover could be made to work)
3/4 "x 3/16" Strap Iron
(usually sold in 4' or 8' lengths from most
hardware stores)
Three attachment bolts: 6mm x 20mm
long.
Three 3/16" spacers, cut
out of steel tube or purchased individually.
One SAE or Metric nut the size
of the cover screw you are using.
Piece of thick rubber for use as
a spacer, and zip tie or glue to secure it.
Drill and assorted bits
Welder, or good friend with one :-)
Beer for the welder friend (or for yourself if
you own a welder)! :-)
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"I
did lots of eyeballing and holding up of the
cover before I started..
I used my noggin instead of a system of exact
measurement. " |
I used my eyeballs and a tape to
measure the differences in lengths of the straps,
caused by the offset thickness of the rear jug.
One had to be shorter. I made the flat mounting
tabs on the ends of the straps long enough that
the rest of the strap would be at least partially
hidden. I even put a little more angle in the
bends to achieve this.
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I
welded the two straps together after cutting the
one to just overlap the other. Could have butt
welded it, but thought it would be a bit stronger
this way. I held the cover up to the installed
brackets, and marked the hole to be drilled in
the strap. . Drilled it then welded a nut on the
back. I held it where it needed to be with the
bolt inserted in the nut. Tack welded it, removed
the bolt, finished welding the nut to the back.
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I
used a piece of tire I cut for a spacer to make
up the 3/16" offset in the bracket straps,
and to give the installed cover a cushion to help
stop any vibration that might occur, used a zip
tie to attach the rubber.
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| I
then cut some 3/16" spacers from a piece of
¼'steel tubing. I used these spacers to mount
the brackets to the jugs. The holes are recessed
in from the fins, and the spacers keep the
bracket from damaging the fins. |
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| This particular
cover uses a base piece that is first bolted to
the bike, then a snap on cover for the finished
product. |
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A little comnon sense, an artistic eye, some primitive
low tech parts, and a will to get it done is all it
takes, and the whole job took me about an hour and a half.
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