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Read More Bikernet Project: Widowmaker Charity Build, Part 4
By Robin Technologies |
We are back at the Widowmaker Custom Design & Repair shop for final assembly of our bike. Everything has come back from paint, powder coat, etc. Now comes the patience part of our build, reassembly. At this point you need to have a plan of attack. Hopefully you took note of how you removed certain items so that your assembly is smooth without and scratches. Let us get started.
Item One: Where to start? I generally start by getting the bike back into a rolling state. But this can all hinge on your choice of engine. For Harleys and most v-twin engines this is the best approach. This is the way we approached our setup with the Yamaha Roadstar drivetrain.
However, if you are working with an inline 4-cylinder metric engine you might want to come up with another approach. What I have done in the past is to lay the engine on the floor, on its side. Tape off the areas of your frame that will be near or possibly come in contact with the frame and lay your frame over the top of the engine, at which time you can install all your mounting hardware. This will make it easier to install the engine without damage to the painted surfaces; however it will make it more difficult to get the bike into a rolling state.
One of the things people overlook is the proper set up of your fork bearing. I suggest going to the fork mfg. to get the proper bearing preload. However, a good rule of thumb is for your fall away to be 1 inch. Real easy to check. With your front end on bike and wheel installed and front of bike off the ground, simply move the front tire to a left turn position from center. From center to the point it starts to fall by itself without assistance should be 1 inch. Make sure you check left and right. Next is to tighten or loosen your triple tree stem bolt/nut until you get the desired results.
Item Two: Now is time for your driveline fitment. At this point I would suggest installing all the parts needed to complete your driveline. Start with your primary (if you are using an H-D unit). Alignment of your engine to transmission is critical. Once all is put together, chain/belt and brake install next.
One of the most common issues we see is improper wheel and brake caliper alignment. If your belt is not tracking true you will eat up belts. If you are using aftermarket calipers, it is critical that the caliper is centered over the rotor. You may have to shim your caliper to achieve this. If you don’t take the time to do this, the caliper and rotor can be damaged after a short period of time riding. Watch what brake fluid you use.. Know what the brake mfg. requirements are. Should be DOT 4 and DOT 5. In our case we were able to use all DOT 5 fluid.
Item Three: Now you’re ready to plumb the bike. Time to install your oil tank and remaining large items, such as your starter, headlight, etc. Plan ahead; you want your oil lines to be not only functional but appealing to the eye. Keep in mind that if you are using stainless steel braided hoses to make sure they are clear of any rubbing issues. A vibrating braided hose can become a saw on top of paint or aluminum. Do not put any fluids in your bike just yet; you may need to remove the tank for ease of wiring.
Item Four: Hands down, the largest area people struggle with is wiring. You can use a stock wiring harness, this works well if you are dealing with a metric bike as we did. However, be prepared to make modifications to the stock harness. I would suggest having a service manual for the brand of engine you are working with. This will make your life easier. If you are not and you’re planning on making your own harness, I would suggest owning a meter and have a clear understanding as how to use it.
I cannot stress enough to plan ahead.
I cannot stress enough to plan ahead.
The best way to handle this is by drawing up your own wiring schematic, making a list of all the items you are using. This will give you a visual to go by. In our case we used the stock wiring harness, with some modifications to make everything work. Then we added a great product, “Grip Ace.”
The “Grip Ace” makes for a super clean and simple install without the dopey look of stock switch housings. If you are not familiar with this product, visit them at www.gripace.com. This product allows you to have all of your bike functions literally at your fingertips of your left hand. The system is compiled of a four button key pad that is installed on your left hand grip and a slim line module that can easily hidden almost anywhere on your bike.
The wiring is super simple. Once your left hand grip is fitted with the key pad, run your preformed wire and plug through your bars and plug into the module. All of your bike functions are wired to the module. The unit comes with clean and clear wiring instructions and easy to follow schematics. On our bike, we chose to keep the system super clean and mounted our key pad to the inside tunnel of the gas tank. As for the rest of your wiring, test each circuit as you assemble it. Try not to rely on butt connectors, solder as many of your wire connections as possible and keep in mind the serviceability of the bike. Make sure that future removal of the headlight and rear fender can be done by unplugging the wiring rather than cutting it.
Item Five: Last pieces of the puzzle, installation of the tins. This can be the most rewarding part of the job, seeing your new bike in all its glory or it can be a bad day and a trip back to the painter. Make sure you take your time in this installation. Make good choices of hardware. I personally like to use rubber washers on painted surfaces so as not damage the paint with the installation of the mounting hardware. Once everything is hooked up, top off your fluids and add only enough fuel to get the bike running. I suggest this in case there is a an issue of a gas leak or oil leak that may require you to remove the tank.
Once everything has checked out, get out and enjoy that first test ride. Make it short, come back, check everything over. Once all is good, pack up and enjoy your new ride.
THE CHOPPER OF CHOPPERS FOR SALE
By Robin Technologies |
This bike represents an upbeat era when choppers were kings and the Discovery Channel made it so.
We are going to attempt to tell the story of the bike, the shows, and the esteemed owner, Hugh “The Chopper” King, the producer/director.
Hugh actually worked for Easyriders, as the video editor/director, while I watched over the magazines. But he moved on to Original Productions. Motorcycle Mania was the first motorcycle show and I got a call. “Who should I recommend?” Dave Nichols asked. I said Jesse James, and the rest is history.
“Tom Beers, the boss of Original Productions, came to me,” Hugh said. “He asked me if I knew anything about motorcycles, and I said I knew everything about motorcycles, which of course I didn’t.”
“I had worked for one year at Easyriders, “Hugh continued, “doing Easyriders home videos, back when Keith Ball was the editor. These videos really captured the hard core, get down, biker lifestyle. So when Discovery came to us about a custom Harley show, I was all over it.”
The industry started flying and the ratings for these shows went through the roof. During filming at an Easyriders granddaddy bike show in Columbus, the Discovery Channel guys interviewed me and they asked what sorta chopper show I would suggest.
I told them about a bike build-off series that would culminate in a test ride from one wild location to another. Tom Beers and Original Productions suggested the East vs. West aspect to Discovery and they signed off on the notion with a competition between Rodger Bourget and Billy Lane.
“It was East Coast vs. West Coast, Old School vs. more streamlined,” said Hugh, “and it would end at a small out of control event in North Carolina, the Smoke Out by Commander Edge, the magnificent creator and founder of the wildest bike run on the planet.”
“Roger built his beautiful machine in honor of his daughter,” said Hugh, “who was killed on a motorcycle on the previous New Year’s Eve. It was very moving. His bikes are mean, man, and they run. The guys rode like bats out of hell, at over 100 mph a lot of the time, from Florida to North Carolina. At one point, Billy hit a big pothole, and flew so high into the air I thought we were going to lose him. That episode was really well received, which was enough for Discovery to order four more, and then seven after that, and 11 after that. There were a total of 44 Biker Build-offs.”
Hugh and I talked from time to time during the seasons. The flurry of action was high and the drive-by builders to be celebrities flew over the top. I remember riding my 2003 Road King to the Laughlin River Run. Hugh invited me to, I believe, the unveiling of this bike, but as usual, I got lost with a girl in the desert and never made it. While at Hot Bike, I attended with my crew one of the season finales to celebrate the builders and their accomplishment. The King presided over the festivities.
In the next episode, we will cover more of the extreme history of the famous Biker Build-offs and the Chopper King. Then we will cover this creation by most of the major Build-off players including Billy Lane, Arlen Ness, Chica, Eddie Trotta, Kendall Johnson, Mitch Bergeron, Russell Mitchell and Joe Martin. Hang on for the next report.
This chopper may end up on eBay, but if you’re seriously interested reach out to Hugh King at: hughk16@gmail.com.
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
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.
Rebirth of an American Classic: Case Repairs
By Robin Technologies |
Before the engine could be rebuilt, the cases needed some additional work to repair a damaged portion of the front baffle. It appears that an unknown piece of debris was wedged between the backside of the baffle and the flywheel which eventually knocked a hole right through the baffle.
Since HD engine cases are made from aluminum, the best method for repairing the hole was to use a TIG welder to fill in the missing material. The hole was located at the thinnest portion of the baffle, so a piece of copper plate was used to cover the hole and provide support for the weld.
The entire case half was then placed in a parts oven set to 400 degrees Fahrenheit for 45 minutes. This helped to bake out the old motor oil which had impregnated the case over the years and ensured that the entire case was at equal temperature for welding. The heating also revealed that there were a number of cracks radiating out from the hole which also needed to be fixed. By the time the hole, the cracks and the casting imperfections had been repaired, I was left with a good deal of weld to grind away.
The backside of the baffle was easy to reach and was ground back into shape with the help of a curved template and a flap wheel mounted to a hand drill. The top of the baffle was much harder to grind with standard tools, so it was necessary to make a custom router bit using an aluminum sleeve epoxied to a ½” four fluted end mill.
Working slowly, I removed about 1/32” of excess weld with each pass of the router. Liberal amounts of Teflon lubricant was used throughout the process. After every pass the chips were removed and new lubricant was added to make sure no damage was caused by the aluminum sleeve riding against the case.
After some final shaping, the repair was complete and I moved onto chasing the threads for all the tapped holes.
Next, both case halves received a thorough cleaning. All the holes were cleaned out with wire brushes attached to a hand drill to remove any aluminum chips and other debris. From there the cases were soaked in warm soapy water and scrubbed with bristle brushes. Then each case was carefully blown dry with compressed air, paying careful attention to blow out all holes and orifices.
Once the cases were clean and dry, the last step was to apply a coat of Glyptal to the inside of both cases. Glyptal is an enamel based sealer, so once it dries, it is tough to remove. To insure that the sealer only coated the intended surfaces, each case half was carefully taped and covered. Once the Glyptal was applied, it was cured in an over for two hours at 275 degrees Fahrenheit. The result was a hard slick coat of Glyptal and a set of cases ready for assembly.
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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The Mudflap Girl FXR Saga
By Robin Technologies |
It all started when a brother was desperate for cash and I bought a basket case Dyna, and with the help of JIMS machine turned it into an FXR. I started to build it for my son, Frank, the tattoo artist, around an old Kenny Boyce-styled pro street frame. Making progress on this build, with a massive upside down Custom Chrome front end, a brother stumbled into my shop and told me about Paul Cavallo and Spitfire Motorcycles.
Paul’s been around the industry for a couple of decades. When the economy tanked, he hung on with his dad and started Spitfire motorcycles. He was struggling and a brother thought I could help by using a couple of his Spitfire components on a Bikernet.com build. I went to visit Paul and was inspired by his non-stop drive to create new components daily, build world-class old school chops for customers, and kick ass at shows all over the country.
Then I was hit with the bike builder blues. My girlfriend left and I was forced to sell my 2003 Road King, leaving me with a ratty rigid Shovelhead and a Bonneville racer to ride. I needed a new girl and a long distance rider. Too often, around the campfire we debated twin cams versus Evos and most of the bros confirmed the solid stature of the FXR configuration. A plan formulated to build myself another FXR. I returned to Paul’s shop to cut a deal on a chassis for myself. Both were stretched, almost single-loop, long-distance riders with Spitfire Girder front ends.
Paul’s team built my chassis in pure traditional FXR style and Frank’s in the pro street configuration. We re-manned Frank’s FXR engine in black and chrome, and I ordered a bone-stock crate H-D 80-inch Evo. Both transmissions were rebuilt by the JIMS crew to be 6-speed overdrive units. I went with chain final drive and Frank used a stock belt.
The overwhelming concept revolved around building a bike that’s a chopper to the bone, but could be easily ridden across the country. My stretched gas tank holds well over three gallons, the oil tank contains nearly four quarts of oil, and I installed an oil cooler for heat waves. The Spitfire bars are held in place with Custom Cycle Engineering dog bone rubber-mounted classics.
I used Contrast Cut Performance Machine grips and pegs for style, yet road comfort. The bike is rubber-mounted for vibration-free riding. I worked closely with David Zemla of Progressive suspension until we configured a shock system capable of affording me some suspension with somewhat limited travel.
The girder is an uplifting quandary. With the Spitfire structure I could feasibly install almost any shock system, with whatever spring rate I decided on. I’m still messing with the gas-operated Rockshox.
I’m missing the best part, the Saddlemen seat. This seat was carefully configured at the Saddlemen manufacturing facility in Los Angeles, from the heavy-duty fiberglass seat pan to the spine-relieving slot, to the better than foam gel, and the ultimate breathing resilient fabric. That puppy is amazing.
The engine is virtually stock with the exception of a Bennett’s Performance-installed Andrews Cam, S&S oil breather gear, and Branch flowed heads, all their state-of-the-art valves and springs, and intake manifold. I ran an Andrews EV-27 cam and Andrews chrome-moly adjustable pushrods for less flex, a new cam bearing and the Branch flowed stock heads, for 8.9:1 compression, 78 cc Branch-flowed chambers, and 75-80 horses at 2,600 rpms.
The bike was built specifically for the road, but with chopper styling. I can’t leave anything alone, or ride a stock bike. It’s against my nature, but I can ride a scooter that will get me there comfortably in style.
For the first time in my bike-building life, I built this bike in bare form, wired it, and rode it for almost eight months. The benefits are immense, since I could make changes and adjustments throughout this road or rode research period. It gave me an extended period to investigate color schemes, build the front fender, break stuff, repair, and outright replace components, including my goofy chain guard.
It’s odd, but even with 2,000 miles under her belt, I still came up with last-minute changes during the paint and powder process. I added a keyless ignition system from Digital Dawg, which proved to be a safety and security feature. The drawback to riding a bare vehicle for an extended period included rust and oil management.
Still, when I assembled the bike for the final time, I ran into rear powder-coated fender expansion, and adjustments to the position of my one-off Spitfire oil bag to prevent chain damage. Maybe a rear belt would have been a wiser decision, maybe not.
Finally, the Mudflap Girl represents the open road. She represents the drawbacks of industry when it takes our girls away from us. And lastly she represents the desire to find our Mudflap Girl at home or down the road.
IRONWORKS EXTREME TECH CHART
Specifications
Name: Keith “Bandit” Ball
Owner: Lt. Ball
Builder: Ballintsky
GENERAL
Year, Make & Model: 2012 Mudflap Girl FXR
Assembly/Builder: Ballorama
Timeline: 8 months
FORKS
Year/Model: 2012 Girder
Builder: Paul Cavallo, Spitfire Motorcycles
Type: Girder
Triple trees: Spitfire
Extension: 9 inches over stock
ENGINE
Year/Model: 2011 H-D
Rebuilder: New
Displacement: 80 cubic inches
Lower End: assembled by S&S
Balancing: S&S
Pistons: H-D
Cases: factory
Heads: Branch O’Keefe
Cams: Andrews
Lifters: S&S
EFI/ Carb: Trock modified CV
Air Cleaner: Roger Goldammer
Pipes: D&D
Ignition: Crane Hi-4
TRANSMISSION
Year/Modifications: 2012 JIMS overdrive 6-speed
Engine sprocket: BDL
Trans sprocket: JIMS 23-tooth
Wheel sprocket: 51-tooth
Secondary drive: Biker’s Choice chain
FRAME
Year: 2012
Designer/Builder: Paul Cavallo/Spitfire Motorcycles
Rake/Stretch: 5 inches up, 2 out
ACCESSORIES
Bars: Spitfire
Risers: Custom Cycle Engineering dog bones
Fenders: Bar Knuckle/Toby/Bandit front, Biker’s Choice rear
Gas Tank: Biker’s Choice
Oil Tank: Spitfire
Headlight: Old spot
Taillight: Donkey from Biker’s Choice
Speedo: Wire Plus
Pegs: Performance Machine Contrast Cut
Electrics: Wire Plus, Digital Dawg (keyless), Biker’s Choice
Seat: Custom by Saddlemen
WHEELS/TIRES
Front Wheel: Metalsport
Front Tire: Avon
Size: 19
Rear Wheel: Metalsport
Rear Tire: Avon
Size:
Hubs: Metalsport
Rotors: Metalsport
Brakes: GMA
PAINT
Bodywork/Molding: none
Painter: Chris Morrison and George the Wild Brush
Color: Super silver
Powdercoating: Worco silver and asphalt satin black
Sources:
Biker’s Choice
BDL
Custom Cycle Engineering
D&D Exhaust
JIMS
MetalSport
S&S
Saddlemen
Spitfire
Wire Plus
J&P Cycles Giveaway Bike – Part One
By Robin Technologies |
Editors note: The following is an introduction to a 5 part tech series which will document the processes used at Bare Knuckle Choppers to transform the J&P Roller with an S&S X-Wedge motor into a street pounding machine to be given away at the 2015 J&P Cycles Open House Rally.
Clocks dictate so much of our lives. My wake up call is at 6am. Checkout is 9am. I’ve been on the road for 30 of the last 48 hours to get to the roller for J&P Cycles’ Giveaway bike. At least before Paul Wideman of Bare Knuckle Choppers (BKC) rips into it. Kate, who’s been with me since Atlanta, is from my hometown near Chicago. She knows me better than myself. She’s also the Sicilian version of Jessica Rabbit, if Jessica could belch like a sawed-off shotgun.
“Quit being a little bitch,” she lovingly encourages me. Since I moved to Raleigh, I missed her Mid-Western charm. I give in, and we pull over after sundown and hit the hotel pool for a couple hours, with a garbage can full of Miller Lites. This is when I lose track of time. In the morning I’m meeting Paul Wideman at the crack of dawn. It’s a good thing I’m not building the bike since there’s only six weeks to do it. Well, that and the fact that only the J&P Cycles Ultimate Builder Custom Bike Show champion gets the privilege—and that trophy belongs to BKC. (You can see Paul’s winning bike in the February 2014 edition of Cycle Source.)
“The roller came in about three days ago. We tucked it back there until you got here to shoot it,” Paul confesses as I get to the shop. It was obvious he had approached it with wrenches in hand, and then had to back away from it. The pro-street style bike looks as if it already has won a couple of ¼ strip races without hitting pavement. All Paul can see is dead weight. Whoever wins the raffle for this bike had better know how to ride fast.
Anyone who has seen a BKC bike knows that there’s nothing you could call an “add-on” or “accessory”. Every part is essential to the operation of the machine. The Bare Knuckle style is purely functional and unapologetically stripped-down. The 117” X-Wedge engine makes the Rolling Thunder FXR frame look beefy, but also brutally fast. Paul gazes at it like a blank canvas- it was obvious the wheels were turning in his head. Like Michelangelo said, “Every block of stone has a statue inside it and it is the task of the sculptor to discover it.”
The BKC Shop is truly a sculptor’s paradise. A row of refrigerator-sized lathes, routers, and presses line the perimeter of the compact factory. Many of them are from the 1950’s. Paul has built some of these machines by hand, so working with a Rivera Primo drive and the 54° triple-cam motor was something he felt he could figure it—although he hasn’t even seen one in person before. As we study the project, Paul has gone beyond the day-dreaming stages of the bike, and is envisioning his ride on finished product. Nichole, Paul’s girlfriend and office manager, snaps us back to reality with a list of new orders. The business and bike build will have to share Paul’s attention.
“I’m known for building choppers and bobbers, so this is going to be interesting… Definitely looking forward to the challenge. This bike deserves it.” Paul philosophized. “Obviously it has just gobs of horsepower. I’m excited for whoever eventually gets this thing.” Paul only has six weeks to take this bike from roller to completion to make the tour for J&P’s Ultimate Builder custom bike show, but Paul is confident, despite it being an impossible timeframe for many shops. To stand next to the man and hear his plan, you would think it is already done. “Go ahead and snap some pics of the shop, whatever you need. I have to chew one of my guys out for being late.” This bike is being created for the winner of the J&P Cycle’s Raffle. You can enter to win at the International Motorcycle Show or anywhere you see a J&P Transporter.
Follow Paul and the J&P Cycles Giveaway bike at http://bareknucklechoppers.com/ and #JPUltimateBuilder and #BareKnuckleChoppers on Instagram and Twitter
J&P Cycles Call Out
J&P is proud to welcome Paul and BKC to their catalog, with more than 10k items available, for the completion of the J&P Cycles Ultimate Builder Giveaway. Zach Parham, General Manager of J&P, is excited to see the final product.
“It’s going to be a great. Paul’s bikes are quite ride-able. We think this bike will be narrow and made to be ridden. He makes the kind of bikes that make someone want to get a motorcycle.I think I’m going to want to take it home for myself.” Zach lamented. Zach and the crew at J&P love customization.
The bikes that you see out at the J&P transporters are actually their daily drivers when they’re on the road, so they know what it takes to maintain a hard-ridden bike. “If there’s one thing we want our customers to know, it’s that we’re structured to get their parts to them in as soon as two work days, including consumables like tires and oil. We like working with builders because we want people feel comfortable working on their own motorcycles, and show them what they can do with bolt-on parts. We have 35 techs on staff ready for calls every day… They can walk you through an oil change or rebuilding your engine.”
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)
Doug Coffey’s RetroMod Panhead Part 1
By Robin Technologies |
Having been in the aftermarket Harley business since 1969, I have pretty much done everything from lacing wheels and custom painting to establishing a performance specialty manufacturing company known as Head Quarters.
Over the years everything in Harley-Davidson aftermarket world has evolved. Today finds old timers like myself better skilled with better tools and far better parts to work with than we had back in the day.
I have built probably thirty motorcycles from the frame up and they have all been builds that kept pace with what the current factory offerings were and the style of the day. The latter builds being Evos and Twin Cams in rubber mount swingarm frames.
That being said, I didn’t find I got the same buzz I used to get when I first started out building those rigid framed choppers back in the early 1970’s.
Some people count sheep to go to sleep. I found myself planning a new rigid frame chopper to send me off to La La Land for a good night’s sleep.
This went on for two or three years before I decided the time had come to act upon my dreams.
After twenty five years of manufacturing performance parts for my company Head Quarters, I realized most of the people I had met over that period had no idea I could actually build a custom bike completely by myself so I decided I would do everything possible in my own shop.
As I preferred the look of the choppers built in the 1960’s and early 70’s but preferred the technology of the parts offered today, I refer to my build as a Retro Mod Chopper combining both old style and new improved parts.
Allow me to show you how this new bike evolved.
The first thing I needed was a frame and I acquired this mid-70’s Shovelhead frame with a Fabricator Kevin hardtail welded on.
Other than the missing sidecar sidecar loops, it has a strong resemblance to a 1957 straight leg rigid frame. Exactly what I wanted.
Other than the missing sidecar sidecar loops, it has a strong resemblance to a 1957 straight leg rigid frame. Exactly what I wanted.
Now it was time to get busy and clean up the frame by cutting, grinding and yes, milling unsightly castings off the frame.
I needed to replace the cross bar for one that would enable me to slide the battery in and out of the oil tank. here you can see it in place ready to be welded. Once I had it tacked in place I was able to remove the original cross bar.
The right side axle plates on the old rigid frames have an elongated slot for the purpose of easier wheel removal. The old bike used drum brakes and the extra length in the slot enabled a long Allen wrench to slide in and remove the five bolts that held the wheel to the drum.
Since I would be using a more modern disc brake wheel I wouldn’t need the long slot so I close it up to match the left side.
Finally a frame back from the sand blaster. If you compare with the original frame you will see I have done more modification work than covered here in these images, I will be explaining some of those modifications over the next few articles
Bennett’s Performance 2004 Dyna Build 106-Incher
By Robin Technologies |
Eric Bennett grabbed the shop door chain and hoisted the roll up door for the first time, in 2000. He started his mechanical career as a certified diesel mechanic with 60-weight always flowing through his blood stream. Finally, he gave into his entrepreneurial spirit and his desire to make motorcycles his life—he opened his own shop on Signal Hill. The rest is motorcycle history, much of it spent at the Bonneville Salt Flats with his dad, Bob.
He recently owned a modified twin cam FLH, but a customer made him a deal he couldn’t refuse, so he let it go. Then a deal on a Dyna surfaced and he made a quick move to snatch it. This time, he decided he would take it to the concrete and rebuild every aspect of the bike to be moderately fast, ultimately reliable, precise, and built with absolutely all the best mechanical intentions and components in mind. You get to see the 106-inch project unfold before your very eyes right here.
One of the benefits of running a service center in the largest city in Los Angeles County includes encountering every possible mechanical malady and the ability to research whatever solution might be necessary. Since LA is also the motorcycle media hub, he has constant opportunities to test anything new on the market. After working on Twin Cams since their introduction into the market in 1998, Eric has watched every configuration, modification, performance recipe, and model roll in and out of his shop.
With this build he could pour every lesson and improvement into his own ride. It started as a bone stock 2004, 88 cubic inch TwinCam. Eric could choose from any hot rod configuration in the world, but he chose to roll with a 106-inch kit from S&S and Branch re-tuned heads. He started the process by installing a JIMS Timken conversion into his left case and welding his crankpin into the S&S lower end after it was balanced.
“With superior S&S flywheels, I didn’t need to monkey with the cases,” Eric said.
He bored the stock barrels from 3 ¾ to 3 7/8 inches and increased his stroke from 4 inches to 4.5. With JIMS tools he pressed in the JIMS race (using green Loctite) (9-59-1) while keeping his fixture perfectly flat and the hole in the race at 12 o’clock.
Using a JIMS fixture tool, he was able to drill guide holes in the case for Timken bearing and race oiling. The JIMS tool holds the drill and guides it. The drills are set to indicate the depth. Otherwise, he would need to use transfer punches and a milling machine. Then he used another JIMS tool to drill for the race fastener holes, and used tap guides to prevent misalignment.
“I’ve made tap guides for every size tap,” Eric said.
One of the benefits of the higher quality Timken lower end bearings is their ability to lock the lower-end into place.
“I have never seen a Timken bearing fail,” Eric said. Until recently Timken’s were used since 1957. “I’ve seen dozens of roller bearing failures!”
The cost saving shift to roller bearings started in 2003 during the 100th anniversary season. “The best Twin Cams were built in 2002,” Eric confirmed. “Better engines, still carbureted and with 1-inch axles for strength and stability.”
Eric used red Loctite on the race screws. He uses a tool for installing both Timken races at the same time. Kelly McKernnan, an amazing machinist out of Portland, Oregon, manufactured it.
The next phase included welding the S&S flywheels. Anytime Eric has a twin cam lower end out of a customer’s bike, he welds the crankpin in place with stainless TIG rod. It doesn’t create much heat and is not a structural weld; it just cements alignment and prevents shifting. He always checks the true after welding.
Next, he installed the Timken bearing by heating the race to expand it, and it slippped over the shaft easily. There is very little endplay in the shaft, just .001-.002-inch. Eric cinched down the top bearing with another JIMS tool, then pressed in the main seal and spacer with yet another JIMS tool.
At this point, we shifted to pressing the new S&S cam bearings into the new heavy-duty Screamin’ Eagle cam plate for hydraulic cam tensioners, but Eric chose to shift to an S&S gear drive system, so he blocked off the oil passages to the hydraulics.
He still ran the larger capacity oil pump with the .585 easy-start cams for midrange power. He could have used the stock plate or SE plate. He also installed S&S piston skirt squirters, which are offset to prevent damage from longer stroke pistons.
He installed Torrington cam bearings in the right case prior to installing the new cams. His plan called for installing a D&D Bob Cat exhaust system, which is 20 pounds lighter than a stock exhaust. D&D pipes come bolted together with all spring clips, flanges, and heat shields in place. “They take like two minutes to install,” Eric said.
“It’s the easiest system I have ever installed,” Eric said. “It comes with the all the components needed and the heat shields in place. No shimming is necessary or egg shaping holes.”
[page break]
Day 2
We took a break for the day and grabbed a beer. But the next day, Eric installed a heavy duty Harley-Davidson pinion shaft bearing kit using a JIMS pinion bearing tool and it was time to slip the cases together with Yamabond on the case edge, while applying assembly lube on the pinion shaft. The case bolts were torqued to 18-22 ft. lb.
“Don’t forget the new oil pump O-ring when installing the high flow H-D pump,” Eric pointed out. Eric has an engine-building quirk. He continually turns the engine over, while rolling through the build process, and constantly tests for changes. “I want to catch anything that might bind early on,” Eric said. We actually ran into a small glitch while installing the cam plate.
But first, he installed the oil pump return gears, and then the separation washer and the spring, before the feed gear. He bolted the cam plate in place with ¼ -20 fasteners torqued to 120-inch- pounds. He used guide pins to help align the oil pump, and turned the engine over while tightening the pump so it would seat itself properly. He tightened two oil pump bolts, then removed the guide pins, and then tightened the other two Allens.
While aligning the cam drive gear dots, he installed the cams and used red Loctite on the drive gear Allen bolts, but used assembly lube on the washer for more accurate torque values and to prevent the bolt from galling against the washer surface for a false torque reading.
As we wrapped up the operation for the day, Eric installed the lifter with the oil holes facing the cam cover, then the guide pins, caskets and covers. No more lifter stools.
[page break]
Day 3
Eric sub-leased a portion of his Signal Hill building to Branch O’Keefe, perhaps the best head porting business in California. I don’t want to put down any performance heads, but Jerry Branch, who is now about 82, built a helluva business around head performance.
Here’s a description of their heads from the Branch-O’Keefe site:
This is where is all began. Branch-O’Keefe is known throughout the industry for legendary cylinder head modification service. Our extensive reworking of stock Harley-Davidson cylinder heads begins with removal of the stock valve seats and guides. Next, the combustion chambers are heliarc welded to add additional aluminum alloy in the combustion chamber and around the valve seats for re-machining.
The valve seat pockets are then machined for larger nickel-chrome valve seats, and the combustion chamber is cut from the stock low compression rectangular shape to the legendary Branch “bathtub” chamber. After cutting the combustion chamber, new oversize valve seats and performance-quality valve guides are installed to tighter than stock tolerances.
The heads then advance to the porting room where the ports are fully hand-ported, blended and polished to Branch’s exacting specifications as proven on the dyno and flow bench. The head’s gasket surface is machined an additional 0.050-inch, which raises compression slightly. Finishing up, new oversize intake and exhaust valves (hard chrome stainless steel with stellite tips, polished face) are installed in bigger seats with a machined race-quality valve job and then hand-lapped. New seals and a high quality high-lift radius spring kit complete the installation.
The Branch O’Keefe head components are damn impressive from the titanium upper collars to the single oval wire spring with more travel and a larger diameter spring material. They have developed heads for JIMS big inch motors that produce 132 horsepower and ft-lb of torque, at an absolutely stock reliability level, even on a B motor. So natch, Eric had John O’Keefe and his master right-hand man, Paul go through his heads. Actually they used a formula they call the Dave Thew head. It’s a nickname for a performance formula. Dave beat everyone with these Branch O’Keefe head configuration. I will outline the different formulas next week.
We started the day installing S&S pistons with wrist pins first, since the oil rings pass over the wrist pin holes. Seems odd, but it’s the nature of the short-skirted piston. “Actually it allows for more skirt on stroker motors and does away with stroker plates,” Eric said. “This piston configuration will keep a stroker running longer.” The oil ring must be positioned with the dimple in the wrist pin area in a particular location to prevent rotation. The S&S pistons use four-piece oil rings with a removable ring land.
Eric installed the bottom compression ring so that the opening faced the exhaust port area. “No gaskets are used on the bottom of the cylinders,” Eric said, “just O-rings.” He compressed the rings carefully, lubed the inside of the freshly bored cylinder and slid the cylinder into place. Then Eric spun the motor over to check for binding. “I can’t wait to hear the D&D pipe.”
Eric started to install the heads using Cometic gaskets. The heads were torqued to Cometic specs and then he set to installing the rocker boxes and the fasteners, which were torqued to 22 foot-pounds. He started from the inside and worked out. Then he slipped in the S&S Quickee-Install intake pushrods for maximum valve opening. “I run premium S&S lifters with travel limiters,” Eric said. “They become solids at high RPMs.”
He tightened each pushrod until the valve slipped off the seat, and then let it bleed down, for about 10 minutes. He backed off the adjustment until he could spin each pushrod (one at a time). Then he backed off just one complete turn or six flats.
These shots were taken before John O’Keefe came up with a crazy notion to machine Twin Cam cylinder fins in a round configuration. Eric was knocked out by the procedure and pulled his barrels for the process.
In the next episode, Eric will slip the beautiful 106-inch Twin Cam into the stock frame, and we will discuss JIMS tools, while replacing the inner primary bearings, the slightly modified Dyna D&D pipe, and then and the new Rivera Primo clutch, the S&S G carb, and a new S&S high flow air cleaners.
Sources:
Bennett’s Performance
S&S
JIMS
Branch O’Keefe
