First off my bikes an 08, I bought a Fatboy style wheel off a 03 XL (Rear). I knew the ID of the bearing would be different but Harley Parts site had 01-14 wheels with all the same part number so I thought Bearings and spacers are all thats different.

Here's where I messed up. Not only is the ID different than mine on the bearing the width of the 3/4 is much bigger than my mine. Also where the bearing rest on the inside of the wheel is too narrow to let my spacer even slide though.

So in my mind I have 3 options.

1.Sell the wheel and try to get my money back.

2.Get custom bearings and machine the wheel to use my axle.

3.Get a 3/4 axle and spacers for my bike (If that will work)

I'm all ears to any help

 

I have an '04 softail wheel in my old Glide, so have dealt with some of what you mention. I had the hub bored through to increase clearance and ID, so I can use a larger diameter inner spacer sleeve and double-row 1" bearings, as per the touring models. Your 'new' wheel probably came with 3/4" bearings, while your '08 bike has 25mm. AFAIK you should be able to swap bearings, after boring out the hub to get the extra spacer clearance, although the spacer length may be different.

In answer to your questions:

1. that is the simple way ahead, as long as you can find a suitable replacement,
2. that shouldn't be necessary IMHO,
3. I wouldn't do that, the axle will be a poor fit in your swingarm.

 

Why can't I just get a 3/4 axle and HD's "Wheel Install Kit"?

 

Your '08 fork legs won't take the 3/4" axle.
AFAIK, I see 3 options:
1) If the inside of the hub won't take your 25mm spacer, have the hub bored out at a machine shop (as mentioned by GRB) and put 25mm bearings in the '03 hub. You might want to check the thickness of the 25mm bearings before going too far. I don't know.
2) Get lower legs from an '04 or earlier and use the 3/4" axle arrangement.
3) Sell the wheel. Tell others what you learned.

 

It's the rear not the front, to accept the 3/4 axle I'd just need the 3/4 swing arm adjusters.

 

Your overthinking it. Bore out the inner hub to allow your inner spacer to fit (the one between the bearings). Get the Harley install kit, it comes with shims to correctly position your new (different thickness) bearings.

 

Rear. Not the front. I see that, now.

 

OK I think this is the route I'm gonna go, I just need to think of a way to bore that hub out.