Number 2 Testors Lincoln Mint Harley-Davidson FXSTS Springer Softail. Kit # 7201

Nolan · 2025-12-08T04:54:41Z

Howdy, it's been awhile since I've had time to work on any models, but I've managed to sneak a few minutes here and there.

After building my first FXSTS Springer model (LINK) I wanted to build another version of it, but with more chopper style. I still have parts left over from my first build, but needed another engine. I found a couple more complete kits on Fleabay. Both are the non-springer version of the Softail, one was missing the tires and the other partially built, but not a failed glue-bomb. I bought both since I’m planning on using one of my 3D resin printed springers I printed during the first build.

I started with the engine. Since I’m building this one as a chopper and am going to use a Dell’Orto carb and manifold, I removed the crankcase breather ports from the cylinder heads. I also filled the gaping opening for the pushrods with some sheet styrene.

I made some cylinder base gaskets from some .005” sheet styrene. Too much work for too little result.

I modeled and printed the manifold for the Dell’Orto DHLA carburetor by Pierfrancesco Di Paolo on GrabCad. It took a couple of tries to get the manifold just right and I had to make several modifications to the DHLA carb, but it looks great compared to the vaguely carburetor shaped blob of the kit carb.

With the engine assembled, I chopped the frame for the ‘Weld-on” hardtail I printed…twice. The first version was too long, which I didn’t discover until after I had installed it to the kit frame. It left too big a gap between the transmission and the rear tire. I carefully broke the resin print away from the kit frame and shortened a new print by roughly a quarter inch. When I modeled the hardtail, I left the frame tube hollow at the ‘weld’ points and filed the kit frame ends to smaller diameter stubs that inserted into the hollow hardtail frame tubes.
I also modeled and printed a copy of the hex oil tank and battery I used to run on my old Shovelhead Harley. I also modeled a chain drive to replace the belt drive used on the model kit.

I tired several times to scratch build an exhaust system using various bits of the stock exhaust and different tubes, but wasn’t successful, so 3D printer go brrrrt. I did some quick filament prints to check the fit, made a few changes and then printed them in resin.

Next up was mounting the Fatbob kit fender. I tried a 3D printed and brass tube fender strut, but too clunky. I ended up soldering brass tube together to make the fender struts.

Cute, but wrong. Too long and wrong angle. So I made them slightly shorter and made a jig to keep them uniform. Solder won’t stick to aluminum so I made the jig out of aluminum plate and aluminum beading wire that I’ve been using to pin parts together and used a Brulee torch to melt the solder. I filled the long tube with aluminum wire to limit how much solder it could suck up to give me a little more control of how much solder to use.
Thanks youtube modeler TimKustom Models for the great tip on pinning parts together.

Removed the fender tabs for the kit struts, mounted some spacers to locate the front of the fender to the frame crossmember, and printed a transmission mount.

Cleaned up the frame and removed the flanges and holes that were the rear gas tank mounts for the Fatbob gas tanks. Oh yeah, and lost the reflector mounts on the frame downtubes.

I decided I didn't want the Sportster tank, mostly because I want to paint this one as a reverse image of the first model, ie. red frame, fender and tank with black scallops and stripes, so I narrowed the stock Fatbobs by a little over 1/8^th inch to make the 5 gallon tanks more like the older 3.5 gallon tanks.

I pinned the fender struts in place, but decided they were still angled back too far, so I moved the holes further forward and slightly lower to raise the fender a bit more.

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More to come, but it will be awhile. Lots of other projects. I plan on doing similar builds on the non-springer Softail models. First, a mild custom stocker, then a chopped version. I also still have several cars in process that I should finish, but I really want to build these Nagano Kawasakis I picked up. Memories of a mis-spent youth. I still dig that '70 Dodge D100 in the background.