1968 Harley-Davidson DE

[jakesnake27]

Ordered a solenoid and reversing contactor today. Still need to get out and look at my accelerator linkage to determine which potentiometer I need. That will be the next thing that gets ordered. This is getting exciting...

[Mooncarter]

Originally Posted by jakesnake27

So I want to get my preliminary solid state conversion thoughts 'on paper'. I want to go to solid state. As much as I would love to simply buy one of Scotty's kits, I just don't have the funds for that. I'm going to keep this simple, keeping the 6 gauge wiring and stock motor.

So here's what I think I'll need:

-Curtis 225 amp 36v series controller
-Potentiometer that matches controller input
-Carts Unlimited reversing contractor for F/R

Does anyone see any flaws in my thinking here, am I missing anything? It's time to bring this old girl into the 21st century, getting rid of the clunky operation and toaster oven parts.

Solenoid?

[jakesnake27]

Originally Posted by Mooncarter

Solenoid?

Yep, remembered it after I posted that. Thanks.

[jakesnake27]

I got a whole lot done today on the old Harley. I gutted the old stuff, and just as I finished that, the mailman showed up. It was Christmas in August.

I was able to get the controller, solenoid, and reversing contactor mounted. Next is mounting the PB-6 potentiometer, SPDT F/R switch, and new key switch. Then wiring it all up so it works (hopefully).

[jakesnake27]

PB-6 potentiometer, SPDT switch, and new key switch are all on the way. Maybe I'll have her running by the end of the week. I will have to do some customization/fabrication to make the potentiometer work with my stock linkage. That, I think, will be the biggest challenge of this entire process.

[jakesnake27]

I made some serious progress on this thing today. Mounting the potentiometer wasn't as bad as I thought it was going to be. Everything is installed except for the new key switch. I'm waiting on that and some copper lugs to come in the mail. Once those come in, we will find out if she comes to life. Stay tuned!

[jakesnake27]

It runs! And it runs beautifully. All that's left is to install the new key switch when it arrives on Friday. This thing drives like a new cart now. Silky smooth acceleration. I'll get some pics of everything on Friday...

[jakesnake27]

The conversion is complete. This is a 1968 cart with a 21st century drive system. I'm really pleased with how the F/R toggle switch worked out. I was able to reuse the original label ring with reverse/off/forward printed on it. The last thing to do is reinstall the splash cover for the electrical components (and maybe clean up the 'engine bay' a little).

[jakesnake27]

I'd like to thank everyone who answered all of my questions that I had throughout this process. Even if I did post them in the electric CC section, when I wasn't actually working on a CC.

[jakesnake27]

My old HD will be getting a roof soon! Today I picked up an 80s gas HD, which will be the donor. The cart itself is a bit rough- it hasn't ran in two years, and it needs an ignition switch, starter/generator, and steering wheel. The roof assembly is solid, but needs repainted. I'll either paint it myself, or have it powder coated white. Attached is a pic of the donor. The cloth part of the roof is not pictured, but I have it. I'll start a separate thread for the gasser once I get to messing with it.