Scored a King Tour-Pak! My refurb project...

[wnt2ryd]

Got the call a bit ago to come pick up the parts, so here they are. Straight out of my truck and onto the ground for some quick pics in the sun :)

They're dusty, but I didn't have a clean cloth to wipe them down. I'm pretty happy with how 3 coats of clear came out.


Bonus: he painted my hard lowers to match

[crazygene49]

Very Nice!

[Monkeyman]

Looks great!

[wnt2ryd]

Started putting things together and as I suspected, the old 194 mini bulbs for the side markers are beyond worthless! Only 2 per side (seriously Harley???) and they make so much heat I was afraid they'd melt the lenses. LED strip lighting to the rescue!

Had to fab some brackets to mount the strips, but I'm happy!

ImageUploadedByTapatalk 21372031117.679353.jpg
Stock regular bulbs.... awful!

ImageUploadedByTapatalk 21372031159.388784.jpg
LED strips - MUCH better!

[ringadingh]

Its coming along nicely.

[wnt2ryd]

Work hasn't allowed me much play time lately, but I've done a little bit of work, mostly rounding up parts:
1) New stainless mounting hardware for the chrome rack, tail light guard, and Tour-pak.
2) Kuryakyn Run-Turn-Brake controller (#4710)
3) Pieces for quick disconnect harness
4) Wire for harness

[wnt2ryd]

While at Lowe's I came across this little beauty, and it's a perfect fit to cover the empty holes for antennas that are present in Harley Tour-Pak tail light housings.

They're in the hardware section in the drawer cabinets. Labeled as "Nissan Push Fastener" but looks like it was made for my purpose :)

[cactusjack]

Originally Posted by wnt2ryd

Started putting things together and as I suspected, the old 194 mini bulbs for the side markers are beyond worthless! Only 2 per side (seriously Harley???) and they make so much heat I was afraid they'd melt the lenses. LED strip lighting to the rescue!

Had to fab some brackets to mount the strips, but I'm happy!

Attachment 4095
Stock regular bulbs.... awful!

Attachment 4096
LED strips - MUCH better!

It's a 22-year old tourpak. LEDs weren't used much for vehicle lighting back then.

[wnt2ryd]

Originally Posted by cactusjack

It's a 22-year old tourpak. LEDs weren't used much for vehicle lighting back then.

I can't argue with you there. I'm making the best of modern technology

[Bud2rat]

Looking good. I would like to see your bike sometime. I live south of Fayetteville. Maybe we could get together and ride sometime.

[wnt2ryd]

Originally Posted by Bud2rat

Looking good. I would like to see your bike sometime. I live south of Fayetteville. Maybe we could get together and ride sometime.

It's a deal Robert! I'm on 401 just up the road from Fayetteville. I actually used to live in Fayettenam, and worked at the Black&Decker/DeWalt plant when it was open. Was a sad time when they closed down

I saw you're from St. Pauls... I passed there many times on I95 while heading to the gokart track in Tarheel, NC.

I'm hoping I might get the trunk far enough to mount and ride over the holiday, so once the rain FINALLY clears out of here, I'm gonna be ready to do some miles!

[wnt2ryd]

If anyone is refurbing their pack and needs a new cover gasket, the HD part# is likely 53415-06.

I'm shocked to type this, but the cheapest source I could find was HD stealerships! eBay had them from $25 to $50, and the HD stealer cost was only $8.89 everywhere I called. Most needed to order, as they didn't have it in stock.

I ended up ordering from http://www.kutterharleyonline.com/ as they had it in stock, didn't gouge me for shipping, and used USPS priority.

[wnt2ryd]

A little more progress tonight, I built a harness to insert between the halves of the brake/tailight plug under the seat. (I HATE cutting stock wiring) This lets me tie in to the electrical system for brake, run light, turn signals, etc and I can return to 100% stock by removing the inserted harness

Lots of parts to make a really simple gizmo...

Big shout of thanks to the good folks at Electrical Connection in Knoxville, TN. Best place I found to get the 6-pin "Hitachi Connector." Great prices, realistic shipping (actual cost, no gouging) and customer service is at the top of their list! If you're wiring/re-wiring and need something, check 'em out at: http://www.electricalconnection.com/

[wnt2ryd]

Harley does some really WEIRD things.... Such as putting a 6.5" grill on a speaker pod that only holds a 4" speaker.

I've heard this isn't a problem in later years, but on my '91 Pak, this was the case. The new Polk Audio 5.25" speakers I bought wouldn't fit

Buying newer pods that hold bigger speakers was an option ($175+) but that wouldn't be sticking with my low-dollar approach.

So I ordered a set of custom cut rings off eBay for $12 delivered.

1) Some prep to the cut edges, as they're all that will show.
2) Primer and paint
3) Counter sunk holes for bolts to mount the ring to the pod.
4) Bolt heads are flush so speaker will mount cleanly.
5) Threaded brass inserts to mount speaker to ring.

[wnt2ryd]

Getting close to finishing up the Tour-Pak, so I mounted the Wompus rack...