Lowbrow Learnins: How-to Make a Hardtail Cut Jig for Harley Sportsters

Written By Rob 'Cycle Monster' Hudnut | 0 Comments

Nov 21, 2024

This tech tip is specifically for helping when installing a 1982-2003 Harley Hardtail Sportster Frame, though the same idea could potentially be used on different frames as well.

This is an alternative method to measuring and marking your stock Sportster frame, as shown in the How-To Sportster Hardtail Install Instructions. You can also watch our Sportster Hardtail Install Video here. Check out our Harley Sportster Hardtail and see why it is the best one out there!

Its easier if you fully strip your bike down to the bare frame. Gather a plate of steel, 3 sticks of steel, (tube, rod, rebar or all-thread), 4 nuts / bolts, a drill, a grinder, a cut-off wheel, a round file, masking tape and a welder or, know an excellent welder.

Grab a piece of cardboard, push it up to the mount surface of the hardtail and stab a screwdriver through all 4 holes. Use this template to create and drill your steel mount plate. Use your nuts / bolts to mount the plate to your hardtail. Make sure its centered and tight.

Next, make sure your 3 steel rods are long enough. Grind one end of each at an angled point. Make sure the pointed end is pointing at the end of the frame tube, not the plug. Holding the tip to the frame, weld the rod to the base plate.

Remove the Jig from your hardtail and bolt it to your stock frame. Use some tape to wrap around your 3 frame tubes. Once all tubes are taped, remove the jig and cut your stock frame. Smile and take pictures!

Now, clean up the inside tubes with a file. Test fit each hardtail plug into the frame tubes it will go into. Bevel the stock frame tubes for an excellent weld. Drill holes in the stock frame to plug weld. You may need to squeeze or spread the lower legs to line up your hardtail. Push your hardtail into your frame. You can use a 2x4 and a hammer for encouragement if needed. Never strike the frame with the hammer directly.

Lay your engine on its side, lower the frame over it and bolt it all up tight. Stand the frame up and begin welding. Make sure all frame welds are pro! Plug weld the holes and joints you can reach. Remove the engine to finish weld. Congrats on your new hardtail!

Download a PDF of this Lowbrow Learnin' by Cycle Monster by clicking here!

Lowbrow Learnins: How-to Make a Hardtail Cut Jig-1

See our other projects how to install Sportser hardtails:
- INSTALLING A 1954 - 1972 SPORTSTER DAVID BIRD HARDTAIL
- INSTALLING A DAVID BIRD 1973 - 1978 SPORTSTER HARDTAIL FRAME
- INSTALLING A DAVID BIRD 1982 - 2003 SPORTSTER HARDTAIL

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Rob 'Cycle Monster' Hudnut

Rob Hudnut (a.k.a. Cycle Monster) is a Portland Oregon native, born and raised in the City of Roses. He has been around the scene his whole life, going to countless car shows, bike shows, races, swap meets and poker runs growing up with his family.
His folks had been riding motorcycles before he was born. His dad commuted to work daily, year round, in all weather throughout his career. His folks were members of the AMA and were corner workers at the local P.I.R. raceway for motorcycle races. His dad was also heavy into the custom car scene and built a full custom, chopped, channeled '51 Ford coupe that he drives to this day.
Rob got started young, working on customizing cars with his dad and older brother Roger. They didn't play catch in the yard much, but the family spent a great deal of time in the garage throughout his childhood. Rob got his first motorcycle in 6th grade. His folks taught both boys how to ride and shift that little 1973 Honda XR75. Later on, he had developed his artistic talents as project cars and bikes filtered into his adult life. Metal flake, gold leaf, pinstripes and leatherworking were all areas that really grabbed his attention and skill. He taught himself how to weld and fabricate and the custom ideas started flowing.
One day he picked up his old trusty pen and paper and drew some motorcycle how-to ideas, which he shared on Instagram. A few how-to's became more. People seemed to dig them and in 2019 he illustrated and self published his first how-to book for motorcycles as "Cycle Monster". His second volume was released in 2020.
Along the way, Tyler and Rob starting working together on commissioned how-to illustrations called "Lowbrow Learnins". Some have been in the Weirdo catalogs while others have been shared online. More is sure to come from Cycle Monster and Lowbrow Learnins!

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