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Read More Doug Coffey’s RetroMod Panhead Part 3
By Robin Technologies |
I needed an oil tank for this build that would be rather unique. It had to hold a full size battery from a late model electric start Dyna or Softail as my large high compression stroker motor would need all the starting power it could get. It had to completely hide the battery because I didn’t want any of it to protrude above the frame rails and it had to hold lots of oil.
My preference was round oil tanks so I started looking for cylinder like containers to see what size might fit.
After testing a variety of ice cream containers and my wife’s Tupperware I found a one gallon paint can to be perfect. (once I cut the bottom out to clear the electric starter)
The first step in making the oil tank was to fabricate a battery box. I used some 14 gauge sheet metal and bent one up on my brake and then welded in the sides. The batteries I use are the late sealed type so they can be placed in any position. This one was going to lay in at an angle to miss the electric starter.
With the battery box out of the way I used some more 14 gauge sheet metal and rolled up the tank on my 3 roll machine.
I cut a rectangular piece out of the tank shell and welded the batter box inside the tank. Now you can see why I wanted such a big tank, that battery box displaces a lot of oil holding capacity.
The under side of the tank had to be notched for electric starter clearance.
With the oil tank shell part taken care of it was time to make some tank ends. I wanted my ends flat so i could later bolt on polished aluminum covers.
After plasma cutting the ends out I drilled holes to mount them in my lathe and turn them round. I need perfectly round ends to help pull the tank shell into shape as i tack welded everything together.
Before welding the ends in place I had to weld two threaded blind bungs in the back sides to attach my aluminum side covers. This was a little tricky as the threaded holes needed to be parallel with the fins on my motor’s right side timing cover as I planned to machine matching fins for the oil tank end cover.
Lower front oil tank mount is hinged to flip up for easy removal. If I need to work on the starter, the oil tank must come out.
Oil tank top mounts are countersunk for Allen cap screws. I do this with all my mounts so I am not tightening bolts and washers against paint.
Time to make those oil tank end covers.
The left side cover had to be notched for the starter drive.
Right side cover test fit and oil tank filler welded in and capped.
I machined and radius cut the exact same fin pattern as the engine timing gear cover on the right side cover. The left side cover was easy as it was all done on my lathe.
I think it was all worth the extra effort.
The RetroMod Panhead is Provided by Doug Coffey with www.Head-quarters.com
Bikernet Bike Build: BETSY’S REVIVAL STORY Part 2
By Robin Technologies |
Oncethat trailer gate hit the driveway back at home I could see tired ol’Betsy begging for another chance at life! As I walked aroundthe trailer she lay resting after the 1500 mile journey back. Iassessed the impending task of making this Ol’ girl right again.
“Rode hard and put up wet,” I said to myself thinkingof all the journeys and adventures she served Scooter Tramp Scotty through.As I took in every line every worn out part of this soul servingmachine I tried to imagine all the places she saw, all thelandscapes, the women who made passenger, the endless white lines stretched for over half-a-million miles. The nomadicvessel of freedom that is this motorcycle I now have the honor ofsorting out to make whole again.
Ilugged the broken pieces of this ’88 Electra Glide into the garageone by one. With an enthusiastic fire burning inside that I’vebecome a master at harnessing, I went straight to rearranging the shop foraccommodation of the new project. The work bench was clearedand the sorting of parts began, one-by-one. The bike “formallyknown as” Betsy quickly became a shell of her former self.The quest to get to her skeleton was my frantic goal, because there iswhere the worst lie waited to be healed. The evening faded to nightquickly and sleep was beckoning.
Tomorrow would be a new daybut with it came the disruptive chore of work so Betsy would laywaiting for my 6:30 return from the daily grind.
Ipulled in to the house with anxious anticipation to strip her down tothat rusted and broken frame.As all parts lay categorized on the bench, I was left staring at 20years of grease and road grime thicker than the remaining paint theMoCo laid down 29 years prior. Before I could send this frameto repair, I had to get the layers of gunk off.
Thoughtsimmediately flooded my mind of just how many states and how manycountries this dirt belongs to! As I started scraping andcompiling clump by clump into the jar my imagination raced again intothe tapestry of visions stretching from Panama to Alaska where thistrusty companion carried her rider faithfully. I was holding inmy hand crust of the earth scooped up by Scooter Tramp Scotty’s gypsyjourneys traversing the entire North American continent for twodecades. WOW!
Nowof course you know all of this has been documented in picturesthrough social media and through that incredible juggernaut I wasable to reach. I announced toFacebook land my intentions with Betsy and the response wasoverwhelming. This resurrection would only be possible withhelp of the great people who reached out to aid in thisreconstruction.
With the frame in real bad shape, it became my first and most important part of the restoration. An unsuspecting buddy reached out to me.Little did I know, he had been following the unfolding of theRevival of Betsy. Mr. Steve Brownell of Brownell Metal Studio, who has been a great friend of mine for a number of years extendedhis professional welding expertise. You see Steve has been inmetal manipulation for over 30 years doing high-end architectural andstructural work for some of Virginia’s finest establishments. Amaster welder and fabricator in every type of metal from brass,stainless, bronze, aluminum and steel, his craftsmanship is upperechelon in the industry.
Bringingthis exhausted carcass to his hands of healing was a no brainer.I asked Steve, “Can you fix her road ravaged frame, brother?”He smiled ear to ear responding, “Of course I can.””I’ll have her back together better than the day sherolled off the assembly line.” My confidence in thisrevival mirrored the words from Steve’s mouth at that moment. Iknew this was the beginning of Betsy’s second coming!
Stevewasted no time in tackling the task. Explaining to me how he had been followingScotty’s adventure, as many have, he was piqued by the ScooterTramp’s offbeat lifestyle and was excited to be a part of Betsy’srebirth. First line of business was tobead blast every square inch of the frame to expose any unseen rot or cracks laying camouflaged beneath the patina’d paint. Steve went towork uncovering what would soon become a little more than a brokenframe rail.
With three portions of the frame cracked and thebottom section of the frame rails looking like Swiss cheese, Stevecut out the cancered sections and replaced those portions withupgraded stainless steel meticulously melding the two metals togetherin one seamless blend of strength and integrity that won’t see rustagain at least in those portions. Hand shaping a few new panelsto replace and reinforce the swingarm junctures and a kickstand mountready for another twenty years of parking lot profiling, restorativefabrication COMPLETE!
Mr. Brownell even offered, as an addedbonus, to give her a two coats of primer, a fresh coat or three ofpaint, and shine her up with plenty of clear. She will onceagain be the prettiest girl at the ball or rally. I only sawthe process in pictures as you are now, but all I can sayis..AMAZING! Putting thirty plus years of quality experiencebreathing new life into a piece of true biker Americana, SteveBrownell, executed flawlessly.
Igot the call about a week after drop off– the surgery was asuccess. The following morning I anxiously drove out toBrownell Metal Art Studio anticipating the unveiling of Betsy 2.0.Upon arrival I had that knot in my stomach as if meeting a girl forthe first time..fucking motorcycle..it was like the morning ofChristmas as a child all over again.
As I walked into the shopSteve met me upon entering with a shit eating grin, I knew it wasgoing to good. I said to him, “I see things went well.”
He replied, “Piece of cake.”
We walked over to theother half of the shop and lying in the middle of the floor restingon a piece of cardboard as to preserve the fresh paint from beingdamaged, sat the old girl. At first glance, I searched for arusted worn out hunk of metal until my gaze fell upon the gleam ofthe newly painted frame sparkling under the shop lights.
HOLYSHIT!..I couldn’t believe what I was seeing I had to double take.As I walked over to inspect Steve’s handy work I looked back at himreciprocating the same “shit eating” grin. I wasfloored. Having to remind myself that this is indeed the samerusted wore out tubes of iron I dropped off a week earlier. Wetook our time and carefully loaded the fresh chassis into the truckmaking sure all was secure and photos were taken.
Ahuge expression of gratitude goes out to my friend Steve Brownell forselflessly donating his time and materials to bring this GypsyMachine back from the dead. As a fellow biker himself Stevereiterated to me a manta I hear and have used time and again, “That’swhat we do, brother.” With a new lease on life I closedthe tailgate behind the NEW girl, gave Steve a big appreciative hug,then drove off waving as I watched Steve and the crew in the rearview sending us on our way to future adventures yet to come.
Onthe ride back home I glanced behind me whispering, as if that framewas my girlfriend, in no time she will feel whole again.
“She’s a cheating Bitch,” Scotty.
Timbo’s ’64 FL Restoration (Part Five)
By Robin Technologies |
Well here she is, finally complete and out for her last shake down run. We stopped at a scenic area and shot a few pictures before I have to hand her over to the owner, Tim. 
I took my buddy Sal along. He’s the only one I have available to kick start this old gal. Sal owned a couple of Pans in the past, and he has the starting sequence down pat! With gas off, kick her through a couple times, gas on, breaker retarded, half choke and a little throttle, and Ka Bam! She starts right up!
Riding the Pan is an art form in itself. The steering is spot on; it will turn on a dime! The suspension is wonderful for the age of the bike. It floats along better than most modern Harleys. The only thing I can’t get use to yet is the pogo seat, feels like it wants to buck you off sometimes.
On the way back from our ride, I noticed a loud noise as I pulled to the stoplight. It’s Sal, yelling at me to slow down, YOUR DOING 85!!
If you followed the articles from the past year and a half, you know that hundreds of man-hours and a little mega money went into this restoration. And I loved every minute of it!
I’d be safe in estimating the restoration at 95% original, give or take a percent or two.
Enjoy the photos, and stay tuned next month when I start another restoration. This time a 1966 Shovelhead, Police special. Here’s a sneak peak!
Hope everyone has a save and wonderful 2013 Holiday season!
–Tail Gunner out till next month.
Doug Coffey’s RetroMod Panhead Part 6
By Robin Technologies |
I wanted rear belt drive on my new retro modern chopper. All the old rigid framed bikes from the factory were chain drive and they were messy and always need adjustment.
After doing a little research I chose the shortest belt available. It was 123 tooth and had been used on the very first rear belt drives Harley offered on Shovelhead models.
After installing the back wheel and belt I discovered I had two problems. The belt was too long and too wide.Later Harleys have narrower belts so I purchased a 70 tooth narrow rear belt sprocket and slit my belt on the milling machine to fit the late sprocket.
I wanted rear belt drive on my new retro modern chopper. All the old rigid framed bikes from the factory were chain drive and they were messy and always need adjustment.
After doing a little research I chose the shortest belt available.
Slitting a wide belt down to 1-15/16.
The skinny piece I slit off my rear belt. I offered it to a friend with an 883 Sportster. He didn’t see the humor. Haha.
If you look at the rear axle in the above picture, you see it is almost all the way back in the axle slot and the adjuster is near the end. This bothered me. A new bike should look like a new bike, not one with a belt stretched to the max.. I needed a fix.
I envisioned an axle spacer (photo above left) that doubled as an adjuster plate and would hide the appearance of the rear axle way back in the slot and the adjuster maxed out. So after a little imagineering I grabbed some stainless steel and headed to my milling machine.
My new axle spacer plates after I finished polishing them.
I don’t know about you but I think that looks a lot better and was well worth the effort.
Rebirth of an American Classic: The Build Begins
By Robin Technologies |
After months of planning, my 1933 Harley-Davidson build officially started on Black Friday. That’s when I made the long trip up to Replicant Metals (www.replicantmetals.com), located a mere 7 hours north of me in Pennsylvannia. Owner Tom Feezer was waiting for me with a set of matched 1933 VL cases when I walked into the shop. These will serve as the basis for my build and are the most important part as the VIN number stamped on these cases is what makes the motorcycle a ’33 model. I plan to stay true to what the factory produced in ’33, but technically anything I build with these cases will be titled as a ’33 Harley-Davidson.
Setting aside the cases, I started making a pile of the other parts: heads, cylinders, cams, flywheels, rods and cam cover. Everything needed a trip through the blasting cabinet to knock off 80 years of built up grease and grime. Before loading up the blast cabinet, some of the parts needed to be broken down further, including the cases and the cam cover.
Starting with the cases, there were still some cylinder studs which needed to be removed.
Normally, I’d just use the old two nut trick to back them out, but Tom actually had a specialty tool from Snap-On for removing them. The tool comes with a number of collets which are sized for different thread pitches and bolt diameters. You screw the collet onto the stud and then slide a collar down over the collet. The opposite end of the collet in threaded on the outside, which allows you to screw a nut onto which forces the collar down the collet. As the collar slides down the collet, it tightens the collet onto the stud. Once the collet is secured onto the stud, you just unscrew the entire set up as one piece. The result is easy stud removal without damaging the stud or the case.
The idler gear and shaft also needed to be removed which was accomplished by first removing the retaining ring which keeps the gear on the shaft. After removing the retaining ring, the idler gear slid right off without any problems. The shaft proved to be a trickier to get out, but we were able to carefully pry it out after threading a bolt into the end of it. Using blocks of wood to protect the case, a small pry bar was slipped under the bolt head to pry out the shaft.
Next I turned my attention to the cam cover, which turned out to be the most complicated part to disassemble. Unlike modern motorcycles, the VL cam cover is used to houses the oil pumps and timer. All of these parts are held in with flathead screws, so special attention was paid not to damage them. The first step was to give everything a get soak in Kroil penetrating lubricant.
That did the trick for all but one screw. In the end, it took careful heating of the cam cover with a torch to break that last screw loose. These parts had enough surface grease on them that the needed to be cleaned in lacquer thinner to get them to a state suitable for putting in the blast cabinet.
Now I had enough parts to get started on the blasting process. The cabinet was filled with a fine grain aluminum oxide medium, which is gentle enough not to cause serious damage to the aluminum. Still, it was important to keep the gun moving back and forth to make sure that no one spot was cleaned to aggressively and to keep the overall color and surface texture even. As a precaution, I also taped over the VIN number just to make sure that it wasn’t damaged as well as plugging all the bushing holes.
About half a day was spent blasting the cases, cam cover, oil pumps, timer parts, connecting rods and flywheels before I moved onto the cams. The V-series engine uses four gear driven cams, much like a modern Sportster, each cam as one lobe which opens either and exhaust or an intake valve. Upon close inspection of my cams, I discovered that the worm gear on cam #4, which drives the oil pump, was damaged.
This is an easy fix if you have a replacement shaft available. On V-series cams, the shafts are pressed onto the gear/lobe clusters, so to make this repair I just had to press out the damaged shaft and press in a replacement. Harley designed these cams with an alignment tab, so they can only be assembled in the correct orientation.
When the repair was complete, the cams went into the blast cabinet to clean up the gears. I was careful not to blast any surfaces that would come in contact with the bushings in the case or cam cover.
Lastly I turned my attention to the cylinders and heads. The cylinders were in good shape, without any broken fins and only bored .005” and .010” over stock. All they required was removing the old hi-temp paint from the external surfaces in the blast cabinet. The heads had some minor fin damage which is very common on flatheads. Fins can be easily snapped off when removing the heads if the wrong tool is used.
Since the damage to my heads was not extensive, I decided to use a die grinder to smooth out the broken fins. Once painted, they should blend together nicely and it will take careful inspection to spot the damaged areas.
The heads were placed in the blast cabinet for final cleaning. To help protect my freshly cleaned heads and cylinders, they were all sprayed with an aircraft primer made by Tempo. Don’t be alarmed by the green color, they’ll get top coated black.
After a few pictures were taken, everything was boxed up to be sent out to the machine shop for inspection. After the machinist gives the ok on these parts, they’ll come back to the shop for a final cleaning to remove any debris left by the blasting process. Then it will be time to rebuild the engine.
Editors Note:
If you would like to contribute to the completion of this bike please use the link below.
This project started on Black Friday of 2013 with just a set of engine cases and will end with a complete 1933 Harley-Davidson VL making a cross country run in the fall of 2014. Already a great deal of progress has been made on the restoration of this motorcycle, but more funding is needed to see this project through to the end. Additional articles will continue throughout the remainder of this build and will result in a complete digital archive which takes the reader through the restoration of a 1933 Harley-Davidson, step by step. By making this information available freely online, future vintage motorcycle enthusiasts will be able to rebuild and maintain these great machines.
We have already gained the support of many of the top compaines in the vintage motorcycle industry. If you would like to see your company’s logo included not only on the motorcycle, but also on every article, please contact me directly to learn more about our marketing campaign and advertising opportunities. EMAIL
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How to replace grips on a Harley-Davidson by J&P Cycles
By Robin Technologies |
Today, J&P Cycles shows you how to replace grips on a Harley Davidson motorcycle. From removing your old grips and adding new grips watch the entire process take place.In this video they use a 2013 Harley Davidson Softail Slim for demonstration but the process will be very similar for all motorcycles that utilize dual throttle cables.
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Doug Coffey’s RetroMod Panhead Part 5
By Robin Technologies |
Back in the sixties the movie Wild Angels came out shortly followed by a soundtrack album with a great cover
One of the bikes on the cover caught my eye. The one to the right of the lead bike has a set of low rise Zee style handlebars. Try as I might I could never find a manufacturer low rise Zee bars. Everything available was four inch rise or higher and it is still the same today.
I decided I would make my own Zee bars for this new bike project.
I wanted a beefier look for my handlebars than the usual one inch diameter so I used 1-1/4 inch DOM tubing and cut the pieces to size on my milling machine.
I made the end pieces from one inch tubing and after welding everything together I finally had some 1-1/2 inch low rise Zee bars
My good friend Ron McBroom from Paughco offered to chrome plate my bars for me and I think he did a darn fine job.
Risers
I wanted handlebar risers that looked just like original Glide risers but I had a problem. Original Glide risers are made for one inch handlebars and my bars were 1-1/4 inch which is 25% larger.
I wasn’t going to let that stop me so I made a drawing of the original Glide risers scaled up 25% larger.
After boring and tapping a hole to 1/2 x 13 threads per inch for mounting, I bolted them into an angle plate on my mill and bored a 1-1/4 inch hole for the bars.
In the picture at right you can see a stock original Glide riser.
After boring the holes for the bars on my milling machine the risers went back on the lathe for turning.
The left picture shows the turning work done including a guide groove for slitting the caps off later on the mill.
The right picture shows the finished product ready for polishing. I also drilled and tapped the holes for the Allen bolts on the milling machine.
I don’t much care for rubber mounted handlebars so I turned some mounting adapters on my lathe.
Mission accomplished.
(it only took me 45 years to get around to doing this)
What the Hell is 5-Ball Racing?
By Robin Technologies |
It all started when my mother ran over my metal- flaked Honda 55 Super Cub with a single shotgun pipe. She stormed into our tiny stucco house in Long Beach and announced, “Get that damn thing out from under my car.” Her car was a massive ’59 Ford station wagon. It was 1964 and I was 15.5 years of age. That Honda was my first motorcycle.
Mom and I didn’t see eye-to-eye on a couple of issues. The day after I graduated from high school, I joined the Navy and was shipped to a heavy cruiser off the coast of Vietnam for three tours. I fell in love, and got married, to my mother’s chagrin (my loves have always played a major part, as you will see). During that time, I bought my first Harley, a ’69 kick-only XLCH with a magneto and no battery.
And so began a life of running wild, building motorcycles, ditching wives, and being involved in Bonneville racing. One of the first bikers I ever met was on a small destroyer, the USS Maddox. Andy Hanson was also building his first ground-up big twin in 1970, and his mentor was the late Bob George. Bob was an engine builder and an innovator. He taught me how to build engines. When I slipped away from the Vietnam War, honorably discharged, while dodging a pot-smuggling bust, I returned to civilian life. I was innocent, I tell ya.
They let me out early if I took a trade course, so I took a welding class at Long Beach City College, so I could rake frames. I took the certified welder course. Once clear of the Navy, I enrolled at the liberal arts campus at LBCC and started taking classes. I worked part time at US Choppers in Inglewood, and built engines and bikes on the side. One of the bikes, a Knucklehead, belonged to a high school buddy, Brad. As we were about to finish this wild chop, a new magazine appeared on the racks, Easyriders.
I wrote the publisher a note about Brad’s Knuckle and Lou Kimzey, the publisher, came to see it. The next thing you know, I was the manager of ABATE, the first grass routes organization fighting for motorcycling freedom in America. Then I became an associate editor of Easyriders magazine. Long story short, I worked for this publishing company off and on for 30 years and built a few bikes during that time. Okay, so during that stretch, I introduced Bob George to the Jammer Cycle bosses, Joe Teresi and Mil Blair.
Bob built a streamliner with two 90-inch Shovelhead engines and wanted to go after Don Vesco’s 314 mph motorcycle world land speed record (the granddaddy of records), but he needed financial backing. He couldn’t do it alone. It became the Jammer, then the Easyriders streamliner always piloted by Dave Campos. About this time, I ran off on my first wife and hooked up with a biker broad, who became the second Mrs. Ball and we had a son. That didn’t last long, either.
I became more of a crazed bike builder, joined a club, wrote more articles and hooked up with a club sweetie, the third Mrs. Ball. That was the era of sex, drugs, and rock and roll. Nothing lasted more than a minute, and she was gone, but what a party we had.
Then in the mid ‘80s, I met the most beautiful redhead on the planet and fell in love. I ditched five girlfriends and married the fourth Mrs. Ball. About the same time, Joe Teresi took over the streamliner effort and Paisano Publications. Keith Ruxton became the engine builder/crew chief and Easyriders readers went after that world land speed record. In 1989, we set a major record at 284 mph, but that wasn’t good enough.
We returned in 1990 with Micah McCloskey, Dean Shawler, Kit Maria, and a solid bunch and brought the land speed record back to America at 321 mph. We held that record for 16 years, longer than any of my marriages, so number four was history.
I took a break and then met number five, Rebecca and so 5-Ball was born as a tribute to her and to all the Mrs. Balls in my life. I finally came to the dire conclusion: Marriages weren’t for me. There would only be five. I started writing motorcycle fiction books and they all fell under the 5-Ball brand. Then as the Internet fluttered to life, I started Bikernet.com, also a 5-Ball entity.
At the time, about the mid ‘90s I would build a motorcycle each year and test it on the roads to Sturgis, often with a bunch called the Hamsters. Then in 2006, we established the 5-Ball Racing Team and returned to Bub’s Bonneville with the first sport-bike Panhead based around John Reed’s V-Bike and Berry Wardlaw’s 120-inch Panhead engine. It was a pure fluke, but Valerie Thompson rode this monster into the record books at a top speed of 152 mph. I was standing on the salt the day the ER record was snatched by the Ack Attack streamliner, 16 years later (342 mph).
We learned so much that year that we decided to return in 2007 with another Panhead. This time, we built an aerodynamic bullet and our notion was to build the World’s Fastest Panhead. We did set another record in our class with a top speed of 162-mph during horrible salt conditions.
I pulled away from the magazine world, but continued to write wild fiction books, and then a Bonneville book around our second Panhead World Record, while building Bikernet.com. Hell, we didn’t know what we were doing. But we did know we were having the time of our lives, writing about motorcycles, building motorcycles, and living the two-wheeled dream.
I wasn’t much for trophies or organized sports. I liked to sit alone and write a story, or tinker in my shop. I didn’t ride with groups much, but enjoyed the open road alone, in search of the next redhead and bottle of whiskey. I’ve tried to live by the code of the west and always be available to a downed brother or sister. And I endeavor to help folks in the industry, and with Chris Callen we promote the Motorcycle Riders Foundation Industry Council.
So, a couple of years ago, a young man approached me and wanted to build an apparel line around Bikernet. I leaned back in my tattered leather chair and kicked my boots up on my Panhead desk. After a shot of Single-Barrel Jack the 5-Ball Racing brand was born. I told him there was no money in it, but Andrew Calogero persisted, while the 5-Ball team prepared for another run at the salt.
While we grappled with designing and building the first streamlined Belly Tank trike for Bonneville, I hooked up another positive element to the growing team, Bob Kay, a man who has lived and breathed the motorcycle business as long as I have. Andrew is the operations and sales arm (rolled 5-Ball apparel into the J&P catalog), while Bob designed a carefully thought-out line of leather goods, and suddenly we had a 5-Ball Racing line of riding leathers.
So, there you have it. We were just a handful of brothers and sisters living the chopper dream, snorting racing fuel, drinking whiskey and running amuck. This year, we hope to roll back to the salt with Ray Wheeler’s 124-inch, turbocharged, Hayabusa-suspended Twin Cam; the 5-Ball 1940 45 flathead with a K-model top end (featured in Cycle Source with an engine built by Departure Bike Works in Richmond, VA), and the JIMS Machine, Paughco, Lucky Devil, 5-Ball streamlined trike. Hang on, because there’s never a dull moment around Bikernet or the 5-Ball Racing headquarters.
Bikernet Project: Charity Bike, Widowmaker Style
By Robin Technologies |
“A man’s got to know his limitations”-Dirty Harry
Out in the country roads of Moriah, NC., people pick their own tobacco, run their own stills and gut their own deer. At Widowmaker Custom Design and Repair, Hank Thibodeau brings that same self-reliant determination to the design and fabrication of custom motorcycles. Hank has been out here creating, chopping, grinding and giving inspiration to anybody with two wheels and a dream for more than ten years. The two car garage workshop he shares with Patrick Murphy and his father-in-law Jimmy Glenn, has produced more original works of engineered art than most million dollar bike shops.
The Widowmaker crew is ready to do everything from rebuilding the top end of your old Sportster, fabricating a set of head turning handlebars, or adding class to your fresh-off- the-showroom floor Milwaukee Iron, by installing Hank’s custom two-into-one pipes. Then giving her the iconic Widowmaker designed and fabricated intake so she can breathe 15 horses faster. Your ride isn’t made-in-the-USA? No worry, Hank has a solid record of having a complete disregard for the national origin of any type of stray bike landing on his doorstep. He’ll take it and improve on your ideas, or, like he did two years ago, just take a crotch rocket, chop it up, lay his magic welding rod upon it and get top prize at the Ray Price Capital City Bike Fest in Raleigh, NC.
Each year for the past eight years, the Widowmaker family had been organizing a very successful ride raising money to help families deal with their child’s medical expenses. This year is different; Hank is fabricating a custom motorcycle which will feature his signature hand made parts recognizable throughout North Carolina as the Widowmaker brand. The plan this year is to sell raffle tickets and raise $25,000 and give five local families in need, $5,000 each, to help with the medical care of their child. We caught Hank early in the planning stages and wanted to share his progress of this project to the announcement of the winner on September 26th at Ray Price Harley Davidson’s Capital City Bike Fest in Raleigh, North Carolina.
Bikernet is going to follow Hank through the process of building a custom chopper and staying within the basic interactions between: cost, skill level and availability of tools. This is the first in a series of five articles in which we will be going over some issues that need to be addressed prior to putting fire to metal or pen to paper.
Here’s Hank layin’ it out straight for you in his words: Set the goal and make a plan…then be flexible while you work towards that goal. Reaching that goal is the successful art of harmonizing your choices with your plans within the parameters set by your skills, or as Dirty Harry would say, “A man’s got to know his limitations.”
Be honest in evaluating your skill level; choose a bike that works within your ability and the tools you’ve got in the shop. For example, I would not recommend a 2005 fuel injected V-twin to anybody but an advanced builder. If your strong suit is not electrical, stay away from electronic bikes. Stick with the basic skills for a basic drive train and fuel delivery. Use the theory of K.I.S.S.- Keep It Simple Stupid. A carbed Sportster has been a simple and proven canvas for decades of custom builders of all skill levels. Carbed metric bikes are getting more attention partly due to popular magazines such as The Horse-Backstreet Choppers and Cycle Source. The metrics tend to lose their value quicker yet remain reliable, but the metrics need a more fluent skill set. Sportster tooling is basic, aftermarket parts are readily available.
Choosing a bike. Choosing your donor can be difficult. However, surfing the internet somewhat simplifies this option. Knowledge is power, knowing people helps. Know your surroundings and what you are willing to do to get what you want. What are you limitations? If you find a great deal on a bike but its 1,000 miles away, is it worth the drive? Consider any time, effort and expense in acquiring the donor bike or parts for your project. Speedy decision making is the key to sealing any internet deal. If you find a good deal, jump on it. There are plenty of up and coming backyard builders, and many are out there in the fast lane. This is where your skillset, tooling, and above all- your planning comes into play. Choosing a bike that best fits your ability is better than choosing a bike that better fits your wallet. Knowing your limitations will save aggravation and keep you from wasting time and money. Decide if you want a running bike or not. Running bikes are easier to start with. You’re trying to re-engineer the bike completely. If you decide an engine rebuild fits your plans, your market for a donor bike expands considerably.
Choosing a wrecked bike. First question, does it run? Look at causes of failure. How bad of a hit did the bike take and where? What are you changing about the bike and how does this affect what your plans are? Is the front end in the frame? Are you replacing the frame? Looks can be deceiving. Frame can be bent. Always check. Where was the impact? What deemed it totaled? What condition is the engine? Compression Test? A compression test tool can be easily found at your local auto parts store. Review the specific bikes requirements before performing the test. Basic actions, remove spark plug, disconnect ignition coil, install tester. Spin engine over with throttle open. Evaluate readings. Every engine has different specs. Know your specs. You should not have a difference of more than 10% from one cylinder to the other. This will give you an idea of overall internal condition. An easy way to decide if you have leaking rings or valves is to squirt some oil into the cylinder. Retest them if you have a poor reading. If your value goes up, the rings are bad and the valves may be ok. How long has it been sitting? Perform a Cylinder Leak Down Test using another tool easily found. This can be confusing to understand. You will have 2 gauges. One showing the air coming into the cylinder, the other showing a percentage of air lost. The more air lost, the worse the condition of the internals of the engine, i.e. valves, rings, etc. Make sure the valves are closed and engine is on Top Dead Center (TDC) for that cylinder. Does it run? Get a grasp on the variables of how long it has sat, what is the overall shape of bike? How many miles? Is the speedo stuck on a certain speed? This is a good indication of speed of impact. Is it water cooled? How will this affect your ability? Can you rework the design of the cooling system? Have a game plan for the bike. What parts will you have to fabricate to use in your build? Again, what is your skill set and tooling for the bike? Plan ahead. How far can your abilities carry you and what do you have to buy or source. Make sure your plans also consider the laws of you state for signals, light sizes, handle bar heights, fork lengths? Look at the overall of the bike. What is damaged, where, why, how come?
In this build, we are using a wrecked ’99 Yamaha Road Star 1600. The insurance company determined the bike was “totaled” based on overall damage vs. cost of repair and value of a repaired bike. The bike was running good and in good riding order. The majority of damage was isolated to the front and right side of bike. Fender, exhaust, tire, turn signal bar, etc. (insert pix here). (talking about points of impact, overall condition and damage). But the overall running works of the bike were intact and in good running order.
Having a plan. For this project, we chose this bike specifically based on availability and cost. Knowing our skill set on the front end, we knew this bike would be a challenge, but be a great build. We already planned ahead. We had a Crafttech frame with a 240 back tire that needed a large displacement motor. The 1600 cc Road Star engine fit the bill. Now this comes into tooling. Keep posted to see how the overall pieces are made to fit. See you next month.
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Bennett’s Performance Final, Maybe
By Robin Technologies |
Bennett’s Performance touts being the performance test bed for all-things big twin performance and handling in Long Beach, California. The team is also very involved in Bonneville Land Speed Record efforts. Unless the California Air Resources Board decides to shut down every California custom or performance shop, they will be burning rods, turning lathes, and twisting wrenches until they die.
I say, “They,” and I’m referring to Eric Bennett, the boss, and his longtime mechanic and Dad, Bob. Other technicians come and go. Plus, next-door are the men, including Jerry Branch, and John O’Keefe, who are the masters of the flow bench and headwork at the Branch O’Keefe machine shop.
All shops big and small in California live in fear of being shut down. But let’s not go there. For a few minutes let’s pretend that freedom rings in this country and our political structure loves folks who build anything from hot rods to custom motorcycles. They even support the notion that loud pipes saves lives, because it’s true. They love it that guys don’t beat their wives or do drugs, that they learn how to work with their hands and create something one-off, which they can ride to work or to Sturgis with pride. Am I dreaming or what?
Eric recently came across this 2004 Dyna and decided to research every performance resource and build himself the best hot rod Dyna on the planet, as a test project for anything performance, for Twin-Cams. He did, and we followed the process on Bikernet.com, and this is the third and last stellar episode. But wait, their could be more, according to Eric’s assessment at this point.
“I need to change the shocks,” Eric said. “They are too low and shifting the weight to the rear. I need to tighten the handling.”
Eric was pushing is Dyna onto his shop dyno as we strolled into Bennett’s Performance, a very clean and well-organized shop, a couple of weeks ago. “I wanted to dyno it one final time without a rev limiter,” he said and discovered a dyno malady. The battery was low. At about 5500 rpms the dyno results didn’t indicate a smooth transition through the gears, but jumpy results. He was dying to try again, but we were forced to take a break.
“We’ve run across jumpy dyno results with other rubbermounted bikes, specifically Dynas,” Eric said. With the dyno fixed he removed his air cleaner and backing plate to allow the carb to float. Then he changed his 48 mm Mikuni main jet to the next larger size, for more fuel, and he retarded his timing one notch. He pulled it twice on the dyno and was proud to watch it jump from 117 hp, and to 119 hp, and 121 pounds of Torque. The power range was perfect for street use.
Eric now has 1978 miles on the bike since he rebuilt and upgraded the engine from 88 inches to 106. Shortly after the bike was completed and running, his dyno pulls indicated 112 hp and 119 pounds of torque, then 116 hp and 118 pounds of torque with a carb change, more miles and tuning.
Our discussion shifted back to handling. “At 100 it starts to wiggle,” Eric said, “There’s too much weight on the back.” He plans to install 14-inch Ohlins. Today, the lower badder look is slipping away for the jacked, terrific suspension, badass, dirt bike, café racer, SOA, go fast appearance.
We discussed the new CCE stiffer rubbermounts for Dynas, which might do the trick. “I still won’t be able to dial-in the handling as well as FXRS, like the Unknown Industry guys,” Eric said. “With my handling issues, they pulled away at just over 100 mph. The front feels fine, but I haven’t decided what to do with my number plate. Newer Dynas have additional gussets, but nothing like the FXR, period!”
He plans to black out the wheels and add Michelin tires, but he loves this engine configuration. “It’s perfect,” Eric said. “I didn’t need to machine the cases or crank up the compression. The cam isn’t radical, and I could run stock cylinders.” Jerry Branch told Eric that engines are like a combination lock. One number off and the system doesn’t work.
He’s currently looking for an ’06 or ’07 Dyna 17-inch rear wheel, and he will run a 160 tire. “It still gets 42 mpg. Reaching more than one horsepower per cubic inch with a naturally aspirated engine. It’s impressive.”
The S&S lower end contains a 4.5-inch stroke with 3 7/8-inch S&S pistons. Eric blocked the Mikuni carb out one inch to allow the air and fuel to atomize more before it reached the intake valves. “It’s a smoother delivery to the chambers,” Eric said. “We were lucky to score a set of Dave Thew heads designed for monster JIMS 116-inch motors by the Branch/O’Keefe team. This combination with 2.02 intake and 1.610 exhaust valves, and some slight porting, coupled with a Redshift .647 lift cam, and 11.5:1 compression gave Dave Thew 132 ass-kicking horsepower and 132 pounds of torque.
Dave’s bike with fat tanks and beach bars could not be beat at the drags.
I spoke to Eric’s dad who talked of his Bonneville bikes and going after a 167 mph record. Eric was the rider. “We couldn’t get over 161, but then I learned about aerodynamics. I gained 9 mph by moving the pipes inboard. We gained another 5 mph when Eric shifted his riding position and tucked one foot behind the primary.” They grabbed a record.
So, you can tell by the smell of go-fast, the posters of Burt Munro on the wall, and the Bennett record next to the counter, that this group is all about motorcycles and folks who ride hard and fast. Hang on for the next report.
Bikernet.com Extreme Bennett’s Performance Tech Chart
Regular Stuff
Owner: Eric BennettBike
Name: Brute
City/State: Signal Hill Ca
Builder: Eric BennettCity/state: Signal Hill, CA
Company Info: Bennett’s Performance Inc.
Address: 1940 Freeman Ave,Signal Hill Ca, 90755
Phone: 562 498 1819
Web site: Bennettsperformance.com
E-mail: Bennettsperformance@verizon.net
Fabrication: Bennett’s
Manufacturing: Harley-Davidson
Welding: me
Machining: me
Engine
Year: 2004
Make: Custom
Model: Twin cam
Displacement: 106 cubic inches
Builder or Rebuilder: Eric Bennett
Cases: H-D
Case finish: Black
Barrels: H-D turned round By Branch
Bore: 3 7/8-inch
Pistons: S & S
Barrel finish: stock
Lower end: S&S
Stroke: 4 ½-inch
Rods: S&S
Heads: Branch #4 Dave Thew mods
Head finish: Stock
Valves and springs: AV&V
Pushrods: S&S
Cams: 585 S&S
Lifters: S&S
Carburetion: Mikuni 48 mm modified by Bennett’s
Air cleaner: S&S muscle
Exhaust: D & D Bob cat modified by Bennett’s
Mufflers: D&D Bob Cat
Transmission
Year: 2004
Make: H-D
Gear configuration: Stock 5-speed with wpc treatment
Primary: stock
Clutch: Rivera Primo Pro Clutch
Final drive: Stock
Frame
Year: 2004
Builder: H-D
Style or Model: Dyna
Stretch:stock
Rake:stock
Front End
Make: H-D Speed Merchant
Model: 2004 Dyna sport
Year: 2004
Length: Stock
Mods: Speed Merchant Trees, risers, grips
Sheet metal
Tanks: H-D
Fenders: stock
Panels: stock
Oil tank: factory
Paint
Sheet metal: nicked Black
Molding: none
Graphics: Nothing yet, maybe pinstriping
Type: Factory
Pinstriping: Maybe George the Wild Brush
Wheels
Front
Make: H-D
Size: 19-inch
Brake calipers: Brembo
FrontBrake rotor(s): Lyndall
Tire: Metzler
Rear
Make: H-D
Size: 16-inchBrake calipers: Stock
Brake rotor: Lyndall
Pulley: H-D
Tire: Dunlop
Controls
Foot controls: Factory stock Master cylinder: H-D
Brake lines: Barnett
Handlebar controls: Factory Clutch
Cable: Barnett
Brake Lines: Barnett
Shifting: Stock
Kickstand: Factory
Electrical
Ignition: Dyna twin cam 88
Ignition switch: H-D
Coils: H-D
Regulator: Stock
Charging: Spyke
Starter: H-D
Wiring: Mostly stock
Headlight: Alloy Art
Taillight: Alloy Art
What’s Left
Seat: Le Pera
Mirror(s): Speed Merchant
Gas caps: Stock
Handlebars: Todd’s Cycle
Grips: Speed merchant
Pegs: Speed Merchant
Oil filter: Hi Flo
Oil cooler: Jag
Throttle cables: Barnett
Fasteners: Unbrako
Specialty items: Custom Number Plate fabricated by Brandon at Speed Merchant
Credits: S&S Cycle, Alloy Art, Speed Merchant, Mikuni Carbs, Rivera Primo, Bikernet, Lyndall Racing Brakes.
Sources