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Seamless 3" Stretched Nacelle Installation Instructions
Please read optional installation below!
bits, cut off tool (for steel), Philips screwdriver, various sockets and end wrenches, star allens
to fit handlebar controls, vice grips. Miscellaneous marking devices. And towels to protect
painted and chrome surfaces from scratches.
1. First inspect the headlight nacelle and verify it has no damage from shipping, Once you
start to modify to fit, it is un-returnable!
2. After placing a towel over front fender and preferably a towel to protect the tank, remove the
headlight trim ring via the Philips screw at the bottom, then remove entire headlight assembly
via the seven (or 8 on some bikes) black screws, unplug from harness and set aside.
3. Using an open end wrench or socket remove the top chrome pot metal trim that covers the
seam between the two original nacelle halves.
4. Remove the chrome handlebar clamp cover via the Philips screws around the fork lock.
5. Remove the four nuts holding the spot lamp assembly, next mark and unplug the wiring from
harness and remove spot lamp assembly and set aside.
6. Remove the original Nacelle halves and set aside. (you must unplug the toggle switches,
mark where they went)
7. Using a set of vice grips, remove the four studs from the triple clamps. (these used to hold
on the spot lamp assembly)
8. Follow the handle bar wiring back to the harness and unplug, making sure to mark where
each side plugged in.
9. Remove throttle side mirror and set a side, then remove two screws and front bracket
holding on master cylinder and let the unit hang. (carefully)
10. Loosen the switch housing screws on throttle side (loosen only), then remove the
handlebar top clamps and slide throttle/switch assembly off the end of the handlebar and
gently rest the handlebar with clutch side intact on the floor next to bike. (preferably on a towel
or something soft)
11. Remove all main wiring harness blocks and plugs from attaching posts, and simply tuck the
harness and plugs between frame and throttle side fork tube. (out of the way)
12. Drill mounting holes in headlight nacelle for mounting bolts, headlight assembly,
and switches. premarked indentions will help guide you, please be sure before you drill,
Use the original nacelle as a guide for hole size and location.
13. *** Very carefully remove 3/16” off ends of top triple clamp using a cutoff tool or whatever
will give you a clean cut. (this is so the new one piece nacelle can slide over them without
binding and cracking the new fiberglass unit)
14. Install toggle switches in new nacelle. (drill if required)
15. *** Carefully install new stretched nacelle by feeding throttle/switch assembly and master
cylinder through the top hole of the nacelle and slipping the nacelle down over the triple
clamps. This is a snug fit so take your time and verify nothing is binding. Beating on
the fiberglass nacelle will crack it!
16. Verify the four holes on sides of nacelle line up with the triple clamp holes. (Modify with
dremel tool if necessary). Reinstall the four studs to hold nacelle in place. (Finger tight is good
at this point.) Measure the distance from the top triple clamp horns (the part you trimmed
3/16") to the outside edge of the fiberglass, make a sleeve to go over the stud this length so
that when you torque down on the nuts you do not apply pressure on the fiberglass or it will
crack. Simple steel or stainless tubing will work great and it allows the pressure to go from the
nut to the triple clamp and not pinch the fiberglass. Tubing is not supplied due to the variances
in trimming measurements from when you cut the triple clamp.
17. Reach into nacelle and bring main harness and connector blocks back into place. (Mount
them back onto there original locations as you plug them into their mate.)
18. Bring handlebar back up and slide throttle assembly back on the end, and then mount the
bars and snug the handlebar clamps, you can also remount the master cylinder at this time.
Feed switch housing wiring blocks through nacelle top hole and plug them back into their
respective locations.
19. Reinstall passing lamp assembly. (It may be necessary to spread the top of the assembly
over the studs to get into place, or you can also remove the top studs and then put them back
when its lined up) Do not overtorque nuts onto the studs, just snug with locktite will do
on final installation!
20. Feed spot lamp wiring between nacelle and lower triple clamp. (you will have to use a
screw driver to gently pry out the bottom of the nacelle to slip wires to the right side)
21. Reinstall headlamp assembly – (some trimming will be required with dremel to slide
assembly into place) Double check your holes line up and your marks are correct before you
cut! (the rubber well nuts might be mushroomed on original nacelle, if so go to Harley store
and get 7 more – do not drill holes larger to make old ones fit) Reinstall headlamp trim.
22. Remove tab from handlebar top cover by gently prying with vice grips back and for till it
snaps off. Install billet chrome block from kit with screwdriver to cover the slot in the cover.
Install plastic edge protectors and trim as needed. Now reinstall the handlebar clamp cover
making sure it slides over the lip in front and back. (Some minor sanding or filing may be
required if fiberglass is too thick in these areas.)
23. Now that you know it fits properly you can take it back apart and perform minor prep
sanding and shaping and paint it to match. This part is made from three separate molds so
some seams may need attention where parts are joined together.
OPTIONAL INSTALLATION
(bypass steps 7 through 22 respectively)
If you choose you can split this part in two halves and install like original nacelle to
bypass most of the difficult steps (You still have to drill and test fit the part prior to
prep and paint), and you may still have to trim top triple clamp or fiberglass due to
variances in fiberglass thickness, however you will have to have custom trim made
to cover the top seam as the original will be too short. We have used stainless from
vintage cars in this instance, and it makes installation as easy as the original nacelle.
The four studs, headlight assembly, and handlebar cover offer enough support to
hold the two halves together and in place. Keep in mind the seam on the bottom of
the headlight and rear on tank side will show and not be covered with trim (Just like
oem)(so cut as straight and thin as possible.) This is a custom part so be creative
with trim etc., The final product will be a one off!
triple clamp
bucket by cutting a pie shape and
flipping it over and re-joining the
pieces, this is a 34 degree rake. Also
the trim is from the hood of a 1960
plymouth and this nacelle was cut
into two halves. (see optional
installation)
