Uploaded November 2025 | Updated September 2026, 4 days ago

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We recently picked up a 2004 Sportster 1200 Custom as part of a package deal. It's a clean, well optioned bike that was destined to be broken down for parts, because the time and money needed to repair the damage to it's engine case would be greater than what the bike would sell for complete and running.
But what if we could come up with a way to repair the damage with no special parts or tools?
A thorough search of the internet turned up no such solutions, but that doesn't mean it's impossible.
So, look at the parts, look at the damage and tell us how YOU would go about making this thing whole again.
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