Harley Springer Front End Tools | Homemade Bushing Press & Shop Tools | Riding Vintage

DIY Tools for Rebuilding Harley-Davidson Springer Front Ends

When I rebuilt the springer front end for my 1933 Harley-Davidson VL, I found it necessary to build a few special tools to get the job done correctly. Two of these tools could easily be replaced with a hydraulic press, but the simple shop-made versions take up a lot less floor space than even a small press.

The only catch is that you need access to a lathe or a friend with one. If you enjoy solving restoration problems with simple shop tools, this article shows three practical tools I built for Harley springer bushings, brake shackles, and powder coat fitment issues.

For more fabrication and restoration projects, visit the Vintage Tech section.

Homemade Harley-Davidson springer front end tools made for rocker bushings, brake shackles, and powder coat cleanup work.

Tool #1: Rocker Plate Bushing Removal and Installation Tool

I decided to have my front end powder coated, which meant everything had to be completely taken apart, including removing the bushings from the rocker plates. When the rocker plates returned from powder coating, I would need to install new bushings, so I designed a tool that could do both jobs.

My basic design used a two-piece tool mounted in a bench vise with a 1/2-inch bolt to press out and press in the bushings.

Lower Tool Half Dimensions

• 1.25-inch aluminum round bar stock
• Drill with 33/64-inch bit to approximately 2.25 inches deep
• Bore pocket to 0.99-inch diameter and 1.25 inches deep
• Cut overall length to 2 inches

This created a pocket to catch the bushing as it was pressed out while still supporting the rocker plate.

Lower half of the rocker plate bushing removal tool, bored to support the rocker plate while receiving the old bushing.

Upper Tool Half Dimensions

• 1.125-inch aluminum round bar stock
• Drill with 33/64-inch bit to 2.75 inches deep
• Turn end to 0.7480 inch diameter for bushing fit
• Length of first section: 1.03 inches
• Middle section: 0.934 inch diameter, 1.03 inches long
• Rear flange kept at original 1.125 inch diameter

Upper half of the rocker bushing tool, machined to fit and support the replacement bushing.

Assembled Tool in the Bench Vise

Once the two halves were finished, I used a 6-inch fully threaded 1/2-inch bolt, one 1/2-inch nut, and two washers. Here is the tool assembled and mounted in the vise.

The two-piece rocker bushing press tool assembled in a bench vise with a fully threaded 1/2-inch bolt, nut, and washers.

To press out the bushing, simply tighten the nut with a socket wrench.

Pressing the old Harley springer rocker bushing out by tightening the nut with a socket wrench.

Installing the new bushing is just as easy. Slide the new bushing onto the upper half of the tool before assembling it.

Important tip: one end of the bushing has a slight taper. That tapered end needs to be pressed into the rocker plate first.

Installing the new rocker plate bushing with the tapered end started into the rocker plate first.

Tool #2: Front Brake Shackle Bushing Tool

I built a similar tool to replace the bushings in the front brake shackle, adjusting the overall dimensions based on measurements of the replacement bushing.

Homemade front brake shackle bushing tool built from the same basic press-tool concept.

Tool #3: Powder Coat Cleanup Tool for Spring Rod Bushings

The third tool was designed to remove excess powder coating that was causing a fitment issue with my spring rod bushings. I decided the best way to clean out the excess coating without damaging the rigid fork was to use the original spring rod bushing with valve grinding compound.

To speed things up, I attached the spring rod bushing to my cordless drill.

Starting with 0.5-inch aluminum round bar, I drilled and tapped the end for a 5/16-inch flange-head bolt. Then I turned down a 1-inch section to 0.35 inch diameter so it could fit the drill chuck. A 0.75-inch threaded section with 1/2-inch coarse threads allowed a nut to clamp the bushing in place.

Drill-mounted spring rod bushing cleanup tool made from aluminum round bar and the original spring rod bushing.

Here it is chucked in the drill and ready to start grinding.

Powder coat cleanup tool mounted in a cordless drill and ready for use.

A little valve grinding compound and the drill does all the work.

Valve grinding compound used with the drill-mounted tool to remove excess powder coating from the spring rod bushing bore.

Shop Notes and Final Tips

These designs are basic enough that anyone with access to a lathe can make them. Always verify the dimensions of your bushings and adjust the design of the tool as needed. It is always easier to go back to the lathe and remove more material than it is to add material back on.