Bike Builds

This was actually one of the easiest bikes I've ever wired. It's not a bad notion to sketch out a wiring diagram with consideration for the placement of the components. Think about it long and hard, then take your time. Below this mess I ran the Hardcore Choppers basic wiring diagram and tips on wiring anything. First, there's the regulator that bolts over the front motormount. I use Compu-Fire regulators for reliability and they are wired not to over-work the alternator. So you plug the regulator into the case for the alternator connection, run a ground strap under the frame where the rubbermount bolts and the final hot wire to the hot side of the battery, or the hot side ...

It was hard to imagine, when we stood in front of the garage doors, starring at a pile of boxes, that somewhere in there, somehow, a custom bike lurked. As it developed, except for a non-existent nut or bolt, the CCI Goliath kit was complete. The chromed quandary, could a novice builder, an average American rider (in this case a bumbling college art professor with limited mechanical experience), Ladd Terry, build a hard running 100-inch custom in a week to ten days?The answer was yes, in eight genuine eight-hour working days (not counting paint and powder coating by Custom Powder Coating In Dallas). Under the watchful eye of K. Randall Ball, aka Bandit, the parts contained within those boxes became ...

Hang on. This is the last of the scintillating segments on building the Sturgis Shovel before I write the treacherous saga of the ride. Somewhere we will publish a feature on the bike in a mag and on the site. Oh, there’s one other tech that will come to pass—hard line assembly. I’m waiting for a CD of images from John Gilbert of Bike Works mag.Fasteners organized and ready for final assembly. So let’s get started. I was burnin’ daylight before the Sturgis run. I saved a ton of cash going with all powder and no additional chrome or polishing. It cost me just $325 to powder all my components for lasting protection. Throughout this article I will point out ...

We're getting right down to the bottom line. Harold Ponteralli, our painter called, "If I deliver the paint can you make it to the show." I assembled bikes overnight for run deadlines in the past, so we went for it. We installed the new sheet metal, ran the oil lines and picked up a few chrome knick knacks from Long Beach Chrome. Frank was on his way to the Bikernet headquarters with a brown bag full of Goodridge hydraulic fitting. The heat was on. The rear brake caliper with Goodridge line installed.I installed the exhaust while Frank custom cut lines to fit each application perfectly. You can see how the man does it in our King tech articles using Goodridge ...

The stock tranny linkage cut to work as our brake linkage. A week ago I worked on the brake controls with some success. After fabricating a mastercylinder bracket and actually drilling the holes in the proper location, it wouldn't work. I needed to turn the master cylinder upside down. I called Frank Kaisler to confirm that it was a remote possibility, it was. I cut another chunk of steel plate, drilled the holes again and dug through drawers to find a pushrod. Nothing. Parts and pieces we used to cobble together brake linkage. The master cylinder in place upside down under the tranny.The stock stainless shift rod cut for a master cylinder pushrod. I used a stainless steel shift rod ...

Every custom motorcycle build is an adventure. It takes me from one crazed time in my wild life to another. Fortunately, I'm not spilling my guts about another woman I lost during a knuckle-busting build. But this build did represent turning points. I'm about to step off into my 62nd year and sign up for Social Security. It also represented our stinky economy, and for the first time I pulled the plug on riding this bike to Sturgis. Imagine for a second, the middle of July. Days were long and hot, and the Bikernet shop boiled with activity. The Sturgis deadline was fast approaching. I needed to plan stops, hotels, food funds and a place to stay in the Badlands. ...