John's 48 wiring

I spent the morning at the chiropractor and wiring up the fender on John's 48. There are a lot of twists and turns in the fender, so it is easier to just put one wire through at first.

With the one wire through, you can solder the tail light and brake light wire to the wire going through the fender and then pull both of them through.

Here is the finished product after a bit of pulling and pushing.

1946 and 1947 wiring flags.

This morning I used up the last terminal that i had bent up. I bent up 150 of these terminals six months ago and thought they would last me forever, i was mistaken. Luckily i had another 150 blanks cut out. These terminals were primarily used on 46 and 47 hds. they are bitchin and just like originals.


anyways, I was completely out of bent up ones and had to make some for the 47 and to fill some orders of different guys working on their own restorals. Here is the tool to do it. check out how the two separate diameters on the pin share a common line.



and here is a finished one. It is very tedious to make each one of these little guys, but I am glad that i do it and happy that our customers appreciate the work.

more nerdy details

Here are the two wires for the headlight on the 42


Here they are made into little nooses. Early pre war nooses look like this. sometime during the war, hd cut back on the generous amount of wire used and had a different looking set up. page down to see what a post war one looks like. This is what the terminals on our original paint 37 and 41 knuckleheads look like.



Here is a pic of the noose being soldered. this works really well and allows you to put the bare minimum of solder onto the terminal. Once you have the terminal soldered up, you can flick it to flin the excess solder out.




HEre are the terminals for the 47 that I am working on. They are a bit different than the pre war ones. I am not sure when they switched. Our untouched 46 and 47 knuckleheads are like this.

1941 Harley Davidson EL wiring details part 1

My friend Mike is finishing up his 41 knucklehead bobber, and asked me for some pics of wire routing. My dad has a primo 41 that is pretty much untouched. The fenders have been repainted, the seat has been changed and the horn was missing, but other than that it is all real deal legit stuff. Oh yeah, the bike only had seven thousand miles on it when we got it.


HEre is a neat pic of the wires that go to the tail light and battery.



Here is an awesome stamp it reads,


"Federal Use Tax
on Motor Vehicle
$1.67
Expires
June 10th 1942
Keep this stamp
posted on Vehicle"

Haveany of you guys seen something like this? I bet they used them on trucks and cars too.




Here is a pic of the dash to headlight wire loom. standard bikes with out spotlights did not have the extra terminal on the up side of the rubber horn bracket. Also 1938 to 1941 upper horn rubbers did not have a middle hole in them, the later replacement rubbers had the hole as do reproductions.

41 Harley Davidson EL Wiring details part 2

Check out how the dash to fork wire is routed. This loom is friction taped to the right side of the head on crash bar under the neck.

HEre are the wires from the handlebar to the headlight.

Coil details.

Check out what is left of the patent decal. The tail light wire, coil to brake light wire and oil pressure switch wire run through the seat post clip, the circuit breaker to coil wire is not in this clip.

1949 wiring part 1

In this pic you can see the asphalt loom that is covering the tail light and brake light wires coming out of the rear fender. I sent the o.g. chainguard to my friend Larry Medwig, so he could copy it and make some 40-57 chainguards.


Check out the asphalt loom that goes around the positive wire, and the two tail light wires.



This is a good pic of the relay wires. The circuit breaker control wire is original. It is the small diameter style, and it does NOT have a Farrel. The inner cable is sticking out the correct length.




Here is a cool pic of the switch to Gen. wires, they are in clothe woven loom. The two relay wires and the relay wire on the generator go into some more clothe woven loom. This is a great pic, take notes. Check out the jam nut on the shift pivot bolt, the way the clutch pedal spider spring is, and the lack of a washer under the front case bolt. and lack of lock washers on the gen.





Here is another great pic showing the neck and the gen. to switch wires. 49 was the only year that used two clips on the steering neck. The wiring on this bike is basically the same through 53 until hd came out with the trumpet horn.

1949 wiring part 2

Here is a good pic of the three wire loom that is routed beneath the return line. These three wires are in braided clothe loom not asphalt loom. Notice the press on oil sending unit cap and the silver paint on the welch plug in the cam cover


In this pic you can see the wire running through a clip and up the seat post. Notice how the Circuit breaker to Coil wire is routed.



Here is the shot that everybody needs to see. The Dash to coil terminal loom has never been removed from the bike judging from the original friction tape on the back bone. I am a little unsure about the wire loom being run outside of the triangle in the frame. I would personally run it through the triangle and into the coil terminal junction. Notice that the dash to gen. wire is taped to the downside of the frame, knuckleheads are taped to the right side. This is a great pic.

Check out how tidy everything is, the speedo light has been removed.

Whoa, you guys will thank me for these pics some day.