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The Amazing Shrunken FXR Part 5

Samson

You’ve been there. You handed the Makita cordless drill toyou’re drunken buddy, and he drilled a hole in your big screentelevision. You tried to wrap the extension cord around his neck andfinish him off. We came close to blows in the garage a couple ofmonths back. I spent days carefully welding chunks of Samson exhaustpipes together to form a one-of-a-kind exhaust system.

All the welds were performed with gas and hanger rod. Thepipes weren’t perfect, but they fit the bill. They were actuallyintended to be prototypes, to be duplicated by a paid professional.After the first pass was completed the pipes fit like a glove,although they were artistically rough around the edges. Nuttboy cameby on his Wednesday afternoon escape, and I handed him a highspeedgrinder and instructed him to round off the welds. I worked onanother project and paid no attention while sparks flew. When he wasfinished he tapped me on the shoulder and said humbly, “Not sure thisis what you had in mind.”

He had ground right through the pipes and left gapingholes alongside most of the welds. In addition, I discovered to myteeth-grinding dismay, that there were still large sections of thepipe ground so thin, that as soon as the torch tip came within 6inches of the surface the pipe melted away. I spent another whole dayfilling the gaps. Who knows what will happen when the struggling bikefires to life. We’ll have the only exhaust system on earth withbaffles throughout.

grinding muffler

That’s not all. The grief continued. I hand made a mufflerusing a portion of a Samson baffle. We purchased a chromed, truckfender tip from San Pedro Muffler and went to work, but after hoursof screwing with the shiny metal we almost shitcanned the unit. Thefender tip was made out of a strange metal, almost pot metal, thatdidn’t seem to take to the gas welding and wouldn’t respond tobrazing. For every hole I filled, another crack lurked. I welded,then smoothed on a bench grinder only to find cracks and holes tofill again. The shorty muffler probably weighs 50 pounds due to thevast layers of welding rod. As it stands, this is a pure prototypeexhaust system. We should use it for testing then shitcan the rankpiece of shit and start over.

CCI
Click to order Catalog!

Frustrated, but pleased with the overall look we were readyfor final metal work. This bike is being built by inexperiencedhands, not professionals, in our backyard garage. Sure, I’ve builtsome bikes, but I wouldn’t consider myself a metal fabricator. I cameup with the initial design and we roughed out elements, but we neededa master metal worker to finish what we started. There are preciousfew, true metal craftsman, who I know. One is Billy Westbrook,another is Jesse James and recently, in the news, we displayed metalwork by Roger at Goldammer (Goldammer Cycle Works Ltd.,www.goldammercycle.com ,1-250-764-8002). High quality workmanship.

They’re out there but not on every corner. I stumbledonto another super-slag artist under my nose. James and LarryFamighetti are Hamsters and own a corrugated steel metal shop inHarbor City, California, called Fam-Art. You’d be tweaked to rumbledown Narbonne Street and stumble across this rusting corner buildingthat’s got to be the oldest swaying dump on the block. Theyspecialize in structural steel (you could never tell it from theircreaking tin shed) for homes and buildings. Large chunks of steel,massive shredders, presses and welders are scattered around the funkylocation that’s reminiscent of the first shack Harleys were built in.

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Nuttboy and I darkened their doors a couple of times toask them to flame-cut a couple of chunks of steel for our fenderbrackets. The more I hung around the more quiet-James began to showme steel components he had fashioned for some of the local riders. Herebuilt and reformed Harley taillights to eliminate all the edges andgrooves, then welded them to fenders so that ultimately there were noseams. The more I gawked at the sculptured parts, that demonstratedhis ability, the more I knew we had discovered a man capable of BillyWestbrook fabrication qualities. We hauled the entire FXR to Jamesthe next week.

left fender panel

narrowed shocks

James relocated the straps in such a way to narrow the shockplacement keeping that shrunken look in mind.

right close-up of weld area

This is a close-up of the right fender strap. It’s beencorrected, reformed and readied for final welds.

right fender strut

under rear of gas tank

We cut and fitted the tank and made the mounts, butJames filled the underside, rear section for a perfect fit.

front of gas tank size

We jacked up the front of the tank and mounted it, butJames filled it and formed the front of the tank to match the customridge along the top. He even made paint work suggestions that I foundinteresting. “If you paint a ridge like this with a light color,”James said, “The ridge will disappear.”

We decided to paint the bike a light House of Kolors pearland create a dark teardrop panel on the top of the tank. He alsocreated and welded fork stops to the neck.

As we rolled out of the shop that day James still hadfinal welds to complete. He straightened out our seat pan, but neededto figure out a mounting arrangement. Finally we needed the CyrilHuze front fender brackets checked and welded into place.

We should have the Shrunken FXR back in our clutches inthe next couple of weeks. We need to finish our rear brake andshifting mechanisms with Giggie from Compu-Fire, fire it up for atest ride and tear it down for paint.

Oh, I need to untie Nuttboy. I need that extension cord.

Avon Banner

tank

The Shrunken FXR returned recently from Fam Art, in HarborCity, California (310-326-2141). They welded, shaved, mounted theseat, manufactured fork stops and saved our poor- construction asses.James Famighetti mounted our Cyril Huze front fender, welded andformed the tabs and informed us that the Avon Venom was too large forthe narrow glide front end. It was our turn to work on it.

seat bracket

seat pan

Note that James mounted the seat pan so that the edges wouldnot touch the frame paint in the future.

fender fill

Like any self-respecting bikers we hate to have a bike, oreven components out of our mistrusting mitts. We had another dilemmathat needed handling. The bike still didn’t have a kick stand, and weused two 2 by 4’s, to hold it upright, when not perched on the lift.There’s a trick to this maneuver. If I backed the Pro Street FXR outof the garage and wasn’t hauling the wood planks, I was screwed. Ifalone, I could stand there for hours waiting for someone to strollpast carrying two 2 by 4s–unlikely. After a couple of unsteadyoccurrences, the bike didn’t move without the wood chips on the seat.You can imaging the major pain in the ass this caused.

front fender

We ordered a weld-on, Sportster style, kick stand fromCCI, and it arrived complete, with all chromed hardware and thebracket to be welded on the frame. There was one problem indetermining the position. The front Avon was a 100/100 18-inch, andwe planned to replace it with a 90/90. We needed to have the finishedPerformance Machine wheel in place.

spacer 1

The Avon Road Runner tire arrived, and we had it installed at thelocal Yamaha dealer. James pointed out to us that our front tirespacing wasn’t perfect so I sliced a spacer to give us about a1/4-inch spacer on the right side of the wheel and about a 3/4 inchspacer on the left. The tire, almost centered, now had clearance, andthe wheel floated effortlessly under the modified Cyril Huze frontfender.

spacer 2

Now we were cleared to install the Hot Match weld-on kickstand.This is a tricky assembly process. First, you need to be absolutelysure you don’t plan to change the front wheel, to a 21, or extend thefront forks. If you do, the kickstand will need to be bent ormodified to fit. It’s not the end of the world, but it will destroythe chrome.

avon tire

The other trick is determining the right position. Here’swhat my feeble brain told me, since the directions with the Hot Matchdidn’t cover positioning, except to recommend that you take yourtime–no shit. First I stood my Road King straight up and lifted theside stand until it was locked in place. Then I measured from thepoint that would touch the pavement to the ground. It varied fromaround 2.5 inches to 3 inches. I noted that the Hot Match lever wasnearly 3 inches shorter from the point of contact to the center ofthe pivot point. I took that into consideration. I also noted that Ihad lowered my King with shorter shocks, then added a larger Avontyre (a 150). Ground clearance was also a consideration.

kickstand in hand

Then we picked a placement area on the frame. Our designcalled for little or no forward controls. I kept the tab under theBDL belt drive system and hidden as much as possible, without beingso far back as to create a balance problem. If the weight is forwardof the kickstand, sometimes it can topple the bike. One otherconsideration. When the stand pops up you need to be able to reach itwith a toe, and it better not ride on the belt, or you’re toast. Makesure to check all that, before you burn any rod.

kickstand held in place

I sprayed the frame rail and the components with asilicone splatter preventative. It obstructs slag from sticking tocomponents. It also made the frame a slipper bitch. I tried settingthe stand end on a socket nearly 3 inches off the deck. Then Iconsidered the differing lengths of the stands and shifted to 2.5inches. Sin Wu was called, from the bedroom, to hold the stand firmlyin place. I marked it, with a grease pencil, then ground the edges ofthe bracket to be welded to the frame. Extra grinding took place toform a snug, metal to metal fit. In order to make all this work weneeded to partially assemble the kickstand without the ball andspring.

The easy-to-read directions called for disassembly, but we left ittogether and used it to hold the bracket in place for tacking. Beforetacking I backed the bike out of the clamp, holding it upright,positioned the bracket in the white grease pencil marks and leanedthe bike carefully until the stand rested on the flat surface. Itlooked cool, so we re-clamped the bike securely, held the stand inplace, protected the belt from hot slag and tacked the sucker withour Millermatic welder. Then we took the stand arm off the bracketand welded it some more. That would hold it securely until we torethe bike down for paint.

kickstand welded in place

The Hot Match unit from Custom Chrome is a well madeprecision unit delivered show chromed. The instructions includedrecommendations to apply anti-seize to the spring and ball. Theyendorse using Red Loctite on the pivot pin threads. We didn’t becausethe bike would be torn down for paint in the near future. The armneeds to be placed firmly over the bracket and pushed into placebefore the pin will ease into the hole from the bottom. It doesn’thurt to have a spare set of hands and someone holding the bike.There’s also a pivot pin set screw to prevent losing that preciouspivot pin and kick stand arm, on a desert highway, in the middle ofArizona.

rear shot showing kickstand

That’s it, except to mention that when we head to thepaint shop, we need to tape off the chrome bracket, so the painterwill paint over the welds but not the chrome tab.

Samson

As you can see this bike is damn close to the spray booth.I need to coerce Giggie, from Compu-fire, to ride his FXR out to theBikernet Headquarters with our mid-controls. Once the Joker Machinehandlebar controls are bolted to the modified bars, we’re ready for atrial run, then off to paint. Stay tuned.

BDL

–Bandit

full bike

CCI

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Custom Chrome ® and Chrome Specialties ® have joinedforces to bring you the most comprehensive product offering in theHarley-Davidson ® aftermarket! At over 1,400 pages and over 25,000part numbers, our 2003 Catalog features everything from nuts & boltsto HR3 bike kits, and sets the NEW industry standard.

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–Bandit

Back to Part 4

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Sturgis 2000 – Part 4-2

 

The Harley shop in Green River didn’t have it, nor did any of the other bike shops in the valley, but there was a shop in Aspen. It wasn’t in the phone book and couldn’t be reached by directory assistance. I called the Harley shop back and was given the number for Aspen Custom Motorcycles. I dialed and there was only an answering machine. Tired and dejected, we rambled back toward town. During one of our last installation attempts, we broke off the stud that held the rear tab in place. Now we needed an auto parts store for a large hose clamp and some rubber insulation to prevent the clamp from tearing through the durable powder coating finish.

We pulled up in front of a Napa auto parts store and parked beside a blue and silver pickup with Krylon letters across the back window, “Aspen Custom Motorcycles.” Inside, a thin man with dark hair and youthful features leaned over the counter wearing a black Aspen Custom Motorcycles T-shirt. I introduced myself and he asked us to follow him. Two blocks away, this guy had his shop set up in a single storage unit stall (970) 544-9419. His undercover shop was complete with three stage creme sealer and we bought his only kit, thanked him and hauled ass for the Swank Hotel.

In front of our room was an outdoor corridor leading to the bar and outdoor pool. I picked up several towels, borrowed a large bucket and we went to work. The first stage was a mixture of water and a strong detergent that was supposed to soak in the tank for four hours. We didn’t have the time and let it set for an hour. In the meantime, the guys in Randy’s room where having trouble with the plumbing. After I flushed the toxic mixture into a bucket, I poured it down the toilet in Randy’s room. I knew I should have stopped, but I was beyond the point of no return. I returned to the bike for stage two – flushing the tank with a strong solvent. Again the remnants of the explosive liquid were drained into the toilet. Meanwhile, hotel maintenance men and managers descended on Randy’s room, where a couple of riders had set up their joint rolling station. Plungers, tools and snakes were moved from room to room. Four rooms were effected and they were going to have to snake down from the roof. Randy shook his head.

“Won’t work,” he said and poured the final stage of thick milky fluid into the tank. This process included sloshing the creamy liquid around the tank for 10 minutes, letting it set for 20, then sloshing again before draining. Randy sloshed and coated the lining of the tank for what seemed to be hours, making sure every crevice received its fair share. By this time evening was upon us. The tank was supposed to dry for 24 hours. I didn’t have time and Randy suggested that we use a hair dryer to speed up the drying process. The instructions specifically warned against the use of hair dryers because the final process was extremely flammable. Randy continued draining the thickening substance back into the bottle it came from, as we pondered the question. At one point, we tried putting the tank in front of the air conditioner to augment the flow, but there had to be a better way.

Finally someone hit up the maintenance crew for a shop vac. As the sun sank, we started sucking the fumes from the tank outside our room.

 

At one point, two girls showed up, one 22 and the other 27. They wanted to smoke a joint and party some, but the fumes held them at bay. Both were wearing shorts and tank tops and carrying shopping bags. One included a couple pairs of spiked heels that they quickly unwrapped and promised to sport for us. One had on a top buttoned up the front over no bra, and her tits were pressed so hard against the mint green fabric that the heavenly mounds creased the material. When she leaned over to slip on the shoes, we gasped in unison. Whatever it is that makes a woman’s body magic to a man, is a wonderful thing unless abused by either party. If a woman minds that a man gawks at the flesh exposed by too little clothing, she should cover herself. These girls didn’t mind. In fact, they enjoyed it and wanted more. We could have given in to them except we had a mission and a deadline. After the girls asked some probing questions and we didn’t respond appropriately, they rolled themselves a doobie and departed.

There was another problem with nubile girls finding their evil ways into our lives. We were staying with 100 of our closest, most gossipy friends in the same goddamn hotel. Speaking of gossip, I hadn’t heard from Zebra for two days. He was supposed to hook up with a pack of riders in Tennessee, and perhaps they roasted him instead of a pig. I didn’t know his whereabouts, but I kept calling his cell phone hoping to hear the number had been permanently disconnected.

At 6 a.m. Friday, the phone rang. Larry the mobile mud slide maker was leaving his room to meet me in the parking lot to lend me gas. I was hoping to sleep in, but noooo. I wrestled my ass out of bed and out to the bike with the tank. After setting it on the bike, it was difficult to tell that it had been through hell the previous day. I mounted it, hooked up the lines and went back to bed. I told Larry never to call me at 6 a.m. again and to keep his gas. I wanted to let it air for a couple more hours. At 9 a.m. we put gas in it for the first time from Howard’s truck, just a quart. We loaded up and hit the first station. We were Denver bound. Some of the guys were heading into the pass above, but rumor was that the straight shot was down to Green River, over to the 70 Freeway and into Denver. It was 30 miles out of the way, but we chose the straightest shot. The freeway is only two lanes wide but it meanders along railroad tracks and rivers toward Vail. We stopped for gas in Eagle and were passed by 30 Hamsters blasting onto the freeway. How they beat us I will never know, but I sent my navigator his walking papers the next day.

We caught the furry beasts outside Vail. Traffic began to bunch up and we kept riding faster, splitting lanes and running the gauntlet between the very fast cars and extremely slow trucks. Treachery was all around us as we crested a pass and could see the dots of a pack of bikes in the distance. The tank was holding and the bike hadn’t burped, coughed or sputtered. It could handle anything I dished out. I turned the throttle and it responded. About 25 miles outside Denver we blew past the guys in yellow and another couple miles down the road it began to rain, then hail. We ducked off the freeway, pulled on our slickers and found a log cabin watering hole.

 

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The Amazing Shrunken FXR Project Part 2

Dr. John

Like the enigmatic fortunes you find inside thosefolded Chinese cookies, our visit with Dr. John–the”frame doctor,” was a mix of New Age mysticism andpractical guidance. The week before, Bandit and Ibrought the rolling Pro-Street frame to the gooddoctor. We gave the him our best ideas of what wethought the bike should become. Basically, we wantedthe bike to fit my body proportions, to shrink theframe around the engine and to still have elements ofa street chopper.

Bandit and I had been trying to create a bike that hada real “signature” identity, yet we weren’t sure whatthat would mean. We tried to convey our concepts withawkward babbling.

Stroking his long, gray beard with a knowing gravity,the doctor calmly listened to our ravings. Eventuallyhe gave us a broad grin through the tangle of beardand said, “Don’t worry, boys, I understand exactlywhat you need.”

We had left the bike with vague misgivings.”Do you think he really has a clue what we want?” Iasked Bandit.

“I dunno,” Bandit said, staring off into the acrid,smog-laden sky.”The guy’s kind of strange, but everyone I’ve talkedto says the guy’s a wizard,” Bandit musedmysteriously.

When we pulled up to Dr. John’s shop, there was ourcreation leaning up against the wall. Not averse tostreet-corner poetry, I intoned, “What a bitchin’fuckin’-lookin’ bike.”

neck

“Man, that bike is really unique,” Bandit exclaimed ina more civilized tone.

As we oohed and ahhed about the bike, Dr. John camearound the corner, grinning. I jumped onto theseat-less bike and grinned. It fit perfectly, betterthan an O.J. leather glove.

“I really think you’ve got something good goingthere,” the doctor spoke with unconcealedappreciation. “I wasn’t sure it was going to workuntil I got into it. The bike began to speak to me. Ithink it’s got the right karma,” the doctor spoke withmysterious gravity.

All this mystery was not without reason. Dr. Johnstarted this trek to ultimate frame adjustment workingat Goodyear Tires. A fortuitous opportunity, sponsoredby Goodyear, for advanced training at L.A. Trade Techgave him the chance to try motorcycle repair.Recognizing that he was more interested in bikes thantires, he began a course in bike repair withinstructor Pat Owens.

Dr. John soon connected up with a bike shop calledMotorcycle Menders. Right away, he could tell that hehad a better-than-average sense of what was needed tofix most frames. Eventually, he opened his first shopin Covina in 1983. In 1990, he moved to his presentlocation in Anaheim.

Dr. John’s expertise is extended to both traditionalstreet choppers and to the more exotic road racebikes, where competitive tolerances and alignmentshave seconds off of lap times. The challenges to hisexpertise in frame adjustment include the extremes ofcreating a bike for a 6’9″ rider and a Harley with a25″ over stock front end. For his own use, he isbuilding a karma-tingling three-wheeler with a VWengine.

garage

In his shop, amongst a tangle of tweaked Ninjacarcasses, “destruction derby” ATV frames, twistedchopper forks and even a mangled Vespa body, Dr. Johnholds court. Side-tracking his stories about gettinginto the frame adjustment business, he mixes conceptsof metal stresses with ideas of mental stresses,Eastern philosophy, acupuncture points, shakras andauras, martial arts movements, elements of a good dietand muscle alignment of the spine.

The conversation stumbles easily into his personalexperiences. After an injury of his own, he explored avariety of methods of pain control, eventually meetingan American Indian psychic whose exotic beautyhypnotized him as much as her cosmic consciousness.Here, a glint comes to his eyes and a wry smile bringsone corner of his mouth up. “A rare beauty,” hemuses. “An aura just like Cleopatra of ancient Egypt.”

Bandit nodded in agreement repeatedly, like thoseDodger dolls that bobble in the back windows of cars,to the good doctor’s banter. Bandit slurped his greentea while listening to enchanting tales spun by theDoctor. While I shoveled in heaps of steaming andspicy-hot Kung Pao chicken, my eyes teared up and mynose started running.

“The magnetic flow is a flux of energy in the bodyof…” The steaming pots of green tea and plates ofexotic Chinese food sent wisps and tendrils dancing inthe air above our table like a chorus of swaying,sensual nymphets.

“The assorted colors of shakra balance…” Thisadventure had the aura of Zeke the Splooty about it.We were on a cosmic motorcycle Magical Mystery tour.

An hour or so later, Bandit and I were back on the 91Freeway with the bike strapped to the bed of hispickup, staring ahead kind of dumbly. “What a trip,Dr. John is,” I said.

“Yeah, but I think he did a great job on the frame,”Bandit said.

“Yeah, cosmic man,” my head was stuck in the ’60s.”What do we do now?” I asked.

“Let’s check out some trippy paint for the bike,”Bandit smiled. “Let’s drive down to Stanton and see ifWes at Venom can come up with something exotic enoughfor this mystery machine.”

“Go for it,” I laughed.

It’s days like these that make bike building seem likethe right thing to do. Bandit slapped in a tape of’60s funk and we were sailing down the road like acouple of latter-day Kerouac and Keseys.

bike

Custom Chrome Banner

“Hand me a bigger hammer, goddamn it,” Bandit hollered across the garage. We were slamming together as much steel as we could to get this Frankenstein of a bike together in time to show it to the crowds at the Queen Mary Motorcycle Show this weekend.So far this week we’ve managed to cut 1.5 inches off the swing arm. This brings the wheel into the back end of the bike at the point of the pivot. We are designing the bike with brevity in mind. We are hoping that the finished impression will be a bike shrunken around the RevTech 88-inch motor and Rev Tech 6-speed. Oh, we’ll have devilish accents here and there, but the overall concept is lean and mean.

fender

To that end, we are cutting off any unnecessary tabs and struts. Of course, everything changes as soon as a UPS box arrives. Joker Machine parts arrive every couple of days. The foot controls arrived. The new front Avon tire should be here Monday or Tuesday. It arrived, we had it mounted pronto and the fender was looking good. I hauled it to Urs who is a master body man and he widened it to fit perfectly. Having the right tools makes a big damn difference.

Samson

A new front tire was called for because the sexy front fender from Cyril Huze was too narrow, since he builds bikes for 19 and 21-inch from wheels and we’re running an 18 (our fault).

grinding

After banging the hell out of the fender to try to squeeze out a fraction of an inch clearance, we decided on a smaller sized tire. We ordered an 18/ 100-90. We hope this will allow us at least 3/8-inch all around.

tank

The new Cyril designed stretched tank arrived with the fenders. We cut out part of the bottom of the tank at the back where the front of the seat is, since every goddamn thing we do is backwards. Every builder in the country stretches bikes, we shrink ’em, so the tank won’t fit without mods. This move helped bring the tank down closer to the engine and since the FXR is short, well you get the picture. The tank tabs are in place and welded.

We decided to use an old rear fender off one of Bandit’s past bikes–a Fatboy. We turned it around backwards, the front end will be bolted to the center of the swing arm. Our next problem was how we were going to hold up the stern. After a lot of head scratching, cussing and phone calls we met with master fabricator James Famighetti who suggested that we create our own struts that will be bolted on the inside of the lower rear shock absorber bolt, then welded to the outside of the fender in such a way as to add to the over all look and strength of the fender and conceal the stock aspects. Mounting fenders to swingarms is treacherous. It will vibrate like a dog attacked by killer bees, so it better be strong and still able to remove for touchup.

pattern

No problem, you say? Ah, ha, not so easy kimosabe! We are pretty sure the strut will have enough clearance for the Rev-Tech brakes on the right side of the rear tire. When you come around to the left side, you’ve got the pully to contend with. So on this strut we added a 2″ dog leg to clear the pulley. I made up the patterns on cardboard and the Fam-Art brothers cut and bent the pieces. Then it was time to fit. We’re getting there.

Belt Drive Banner

The BDL pulley from CCI is smaller than the one we used for the mock up. So with our fingers crossed, when all these parts come together this week it will be amazing if they all fit. They did, well, perhaps not perfectly, but we’re getting close.They did, well, perhaps not perfectly, but we’re getting close. If not, “Bandit, get me a bigger hammer, goddamn it!”

Here’s the score. The fender needs tabs and it’s ready. The rear fender needs rivet removal and the massive tabs tack welded. The shock tabs have been cut since the Progressive Suspension shocks from Custom Chrome need to be set wider away from the fender tabs. Let’s see if we can make it to the show. We’re still waiting on Huze oil tank mounting tabs.

Avon Banner

ladd & bike

The saga of the Amazing Shrunken FXR continues. This project is notonethat is merely slapping together after-market products to build a facsimileof a customized Harley-Davidson.From the start, Bandit and I sought to create a unique ‘signature’ bike.Even though we have used a lot of after-market products, most have beenmodified to fit our design plan. The products we use, from the FXRPro-Street frame to the Rev-Tech engine to the Joker Machine qualitycomponents, to Cyril Huze, Avon and BDLare some of the finest products available.

Custom Chrome Banner

Because some of the fundamental elements of design were modified, we havebeen constantly fabricating new brackets, tabs, mounts, and studs. Eachmodification created new issues relating to the fit and function of thedrivetrain. It seems as if we’ve bolted and unbolted the elements of this bike ahundred times.For example, the frame was modified by Dr. John to fit the Rev-Tech engineinto our overall design concept. The top motor mount was bent to fit thenewspacing. We used this motor mount point to position the Cyril Huze teardropgas tank. When we positioned the tank we related it to the handle barclearance at maximum turn position. Rubber mount brackets were welded inplace. The tank was cut at the underside back end to fit low on the frame.It looked hot. Next I cut the La Pere seat pan to hug the pointed rear ofthe gas tank and strengthened the seat back. There is a continuousdouble-‘swoop’from the handle bars to the back of the rear fender. The seat pan lookedhot.

Belt Drive Banner

Then we tried to put the engine in. It didn’t look fit. The engine wasmere fractions of an inch from fitting. Even if we could have hammered itinplace the subsequent tight tolerances would surely create problems as thebike rattled and roared down the road.

bradweld

At this point, we cut the original tank brackets and repositioned themodified tank a little higher on the top frame tubing. The tank looked hot,the engine fit, but now the handle bar swing is a fraction of an inch tooclose to the tank. This means we will probably have to have custom handlebars.

It still looks good and we’re still optimistic. Even as wedroppedthe tank down on the new rubber mount brackets and began putting in the5/16″bolts, we found that the right rear bolt was too long to fit. So we got abolt with a thinner head and with my small fingers, I got the bolt in andstarted. We were still looking hot.

We decided to see if the belt fit since Bandit had cut andrewelded the swingarm 1.5 inches shorter for that Amazing Shrunkenlook. Bandit said no, the belt wouldn’t fit. It wasn’t suppose to. Isaid it looked close. As welooked at the bike we realized we’d had to remove the engine, drop thetransmission, which meant we’d have to support the swing arm. It alwaysseems harder than hell to make something easy. So with a couple of scissorsjacks, hunks of wood, and a crow bar, we were able to loosen the rubbermounton the left side of the pivot point of the swing arm. Then we gingerlyslipped the belt in, put the rubber mount back and bolted everything backtogether. Damn! It fit perfect and we were looking hot.

Avon Banner

Wait a minute. The right side of the belt was almost touching the edgeofthe back fender. Quick surgery with a saws-all cut a chunk out of thefender. Fender fits, belt don’t rub, bike still looks hot.

oil tank 1

As we cram more operational parts together, the room to move gets lessandless. Next we positioned the oil bag, which also brought up the issue ofthebattery accessibility. With bungee cords, a busted yard stick and some woodshims, we finally got the bag in what seemed a reasonable position. Fourrubber mounted brackets were fabricated then welded into place. It lookedHot. Everything was bolted in place. And everything looked Hot.

oil tank 2

Ah, but not so fast kimosabe. We shaved the fins off the back ofthe oil bag for more clearance. With the two rubbermounts in place atthe rear of the oil bag under the seat pan we had enough clearancefor the battery, in the front for the engine and exhaust, under itfor the starter motor, but no clearance for the ever moving rearfender. It needed at least 1.5 inches of shock play since it’sattached to the swingarm. We had to peel the bag out of the frame andtake it to the Famighetti’s metal fab shop, Fam-Art, for theirexpertise. They came up with a plan to scoop out the back of the bagto the battery box without shortening the overall look of the bag.Then the fender will have the clearance to move with the swingarm andstill look hot.

Next, we neet to investigate whether the Joker controls canbe mounted mid frame. At the same time we will begin fabrication ofthe Amazing exhaust system. It’s gotta be lookin’ hot one way oranother.

Samson

–NuttBoy

To Continue……..

Back to Part 1……..

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Sturgis 2001 Buell

 

It’s part of our job as moto-journalists to try what’s outthere in the American market and report back. The ultimate test is to take a bike, customize it and ride it to Sturgis. What could give you a truer test of a bike’s ability to look cool and endure a long run? I’ve been fortunate enough to customize and ride everything from nearly bone stock bikes to ground-up customs. Each trip is an adventure. Each run has varying characteristics, and with each journey there’s a new woman, but that’s my problem.

 

This year we needed to make a choice. I had a Kenny Boyce ProStreet frame that I planned to load a Twin Cam engine into and rideto the Badlands. I also had a 2000 Buell M-2 and I had recentlyinstalled dual Mikuni carb heads on my ’48 Panhead. Since I’m alsoworking on a Pro Street custom for Dr. Ladd Terry, the Bikernetmorale officer, I decided to hold onto my Pro Street project for nextyear. Another doctor, Dr. Hamster, had been working on his 34 VL andwas excited about riding it to Sturgis. We both knew that the antiqueride would be a long shot.

 

On top of the time/money consideration, I enjoy riding the M-2. It’s the hotrod of Harleys, light, agile, brakes like a madman and hauls ass. The guys at Harley like to refer to Buells as their street fighters. I have to agree. So I decided that I needed to put some miles on it and experience its ability for distance. Like last year when I told folks that I was going to ride a rigid toSturgis, I got the same reaction to the Buell. I rode it toLaughlin with a passenger and soft saddlebags. The bike handled likea dream. At 100 mph, it was more stable than most Big Twins, andacceleration was always at hand. There’s no hesitation from zip to 100 mph, and that’s my riding range.I was advised at one point to put a smaller pulley onthe rear for lower rpms while cruising. Later I found that themodification had its glitches. I found that the bike was glass smoothat 100 and still zippy and that was good enough for me. We began aseries of mild mods with a cam change to the Screamin’ Eagle raceversion and added the stainless race header. My partner to Laughlinhad a blast and was so comfortable she passed on several rest stops.We kept going and ran out of gas in the desert. So you can understandwhy there’s a new woman each year. She’s still out there somewhere.In the final analysis the decision was made to ride the Buellto the Black Hills Rally.

If you’ve read the techs, you know what wedid to this puppy, so I’ll go beyond the build to a few conceptionsabout Buell. First, there is no fairing to speak of, but I actuallyfound the bike extremely comfortable to ride. The little chin fairingkeeps the big blast off your chest and I didn’t need anymore. I mayregret those words as I hit the Colorado monsoons, but so far, sogood. Some guys complained about the sitting position, but I found itcomfortable once I knew how to sit. Like any bike, you need to findthe groove. The brothers talked about leaning on the bars and toomuch weight on the wrists. I found that if I leaned over the bars Iput excessive weight on my grip, but if I sat on my ass, it was nodifferent than other bikes, although under hard braking situationsyou are thrust forward.

 

Some felt the ride on a Buell would be rough, yet most wereunaware that the bike is basically a rubbermounted Sportster, andincredibly smooth, especially at 80-100 mph.

 

Others thought I mightlook ridiculous, and I told them I look ridiculous all the timeanyway. What difference would this year make? Others don’t like midcontrols. If you’re not used to them, you may find that you need toadjust, but once you get the hang of them, you’ll find less pressureon your back.

 

Alright enough perceptions and conceptions, let’s get readyto ride. The Buell has 400 miles on it since we made thecosmetic changes and cured some rocker box leaks.

This last week weinstalled Joker Machine billet and anodized turn signals on it and hidthem as much as possible.

 

We picked up a small oil cooler from ChromeSpecialties and installed it with longer oil lines at the front ofthe bike. The oil capacity is about 2.5 quarts, which always makes menervous, so we changed oil and plugged in the largest Dyna oil filterwe could find. The filter and cooler combination allowed us to squeakin 3 quarts and take some precarious kinks out of the lines. I alsostopped by Joker Machine and they liked the mods so much they told meto run one of their point covers or die.

 

Dewey’s Custom Pegs makes thecleanest air cleaner cover on the market and it fit like a dream.Finally we ordered a chrome hardware kit for the rear pulley. While disassembling the rear wheel, we polished the right wheel spacerand the belt adjuster guides–not bad touches.

So Sturgis 2001 is one week away. If I collect enoughaluminum cans off the beach I’ll have a pile of quarters for spendingmoney. The woman in my life is the best candidate to run Bikernetwhile I’m on the road, and I’m ready.

 

This is our quest each year,to build a vehicle and make it to the Badlands to talk about it. I’llhave a full report upon my return. Hang on.

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1928 Shovelhead Comes To California Part VIII

 

strokers

 

deacon coming torwards 500
Master builder and mechanic, Deacon, from Pro-Street in Oahu.

Bob Kay. from American Iron Horse. was a bro and shipped the retro Shovelhead. from Strokers in Dallas. to LifeStyle Cycles in Orange County, California along with a new batch of Dallas Choppers. It arrived the day before a handful of weary travelers stumbled into Los Angeles. on their way home, from Sturgis, Glen and Kerry Priddle were headed back to Australia after spending almost a month, with a dozen Aussies, roaming the mid west.

 

chase & shovel on lift 500
Deacon’s son Chase and the 1928 Shovelhead.

Deacon, his son Chase, and the son’s girl Amanda rode several thousand miles averaging 95 mph wherever they rode. Deacon and Chase are both master mechanics. The ol’ man’s shop, Pro-Street, is located on Oahu, (808) 236-0405 and he’s negotiating with Billy Lane of Choppers Inc. to build engines for Billy’s Discovery Channel Bikes. His son is working in Oregon, but as soon as he returns, he’s packin’ his shit and heading back to the islands.

 

motor right side 500
JIMS machine rebuilt and detailed the engine. It was sharp and runs like a top.

 

charger on battery 500
Charging and checking battery connections.

 

deacon working 500
Deacon checking the solenoid.

Deacon rolled into the Bikernet Headquarters just as the Shovel arrived and we attempted to fire the beast to life. I moved the seat forward, detailed the front end and charged the battery. But, even with a fresh battery, she wouldn’t engage. Deacon suspected the aftermarket solenoid. Seems the spacers and gaskets are too thick, just enough to prevent the solenoid from grabbing the shaft. I trimmed the gasket with an Exacto blade and Deacon ground the face of the spacer. Installed, it worked like a champ. We took it for a ride.

 

deacon and harbor 500
Los Angeles Harbor and our first roadtest.

 

coil 500
First Deacon checked the connections and voltage at the solenoid. He also shorted across the leads with an Allen wrench to see if the circuit was operating properly.

 

coil closeup 500
The solenoid replaced after the gasket around the base was trimmed and the spacer, behind the unit, shaved. Worked perfectly.

 

deacon riding 500
Checkin’ the gears.

It was impossible to jam the suicide shifter into nuetral once the bike was running, even while rolling. Deacon and chase adjusted the clutch, and recommended a Rivera, old school, clutch pack to eliminate chatter and afford the rider smoother shifts. The clutch wobbled and was too tight to find neutral. They loosened the springs until only a thread showed past the adjustment nuts and the spring retainer ran true.

 

clamp on pipe 500
Can you see the cracks?

 

welding 500
The Millermatic 175 hard at work.

 

grinding 500
Deacon built a bead then ground it smooth as a baby’s ass.

 

tip on bike 500
The tip installed, solid as a rock.

I developed padded fork stops and while running we noticed that the clean, handmade, Stroker’s pipe tip was rattling with only one bolt holding it. Upon removal we discovered that the area around the installation nut had already cracked and Deacon grabbed the Millermatic. He welded the cracks and nut for more strength. Then we discovered that the tip shelf was too small, so the pipe end had a tendency to vibrate. Deacon went back to the welder and built a bead around the outside, of the shelf, then ground it to fit. A much cleaner/tighter fit, and the pipe didn’t require an additional fastener.

 

holding emblem 500
Anybody know how old this cast bronze emblem is?

While in Hawaii at the first Choppers Only Show in Wakiki, I gave Deacon, the promoter, a handmade belt buckle for being a gracious host. He returned the favor with an old license plate doodad from the Antique Motorcycle Club. It was destined for the Shovelhead.

 

oil in pan 500
While testing the shifting, clutch and tranny, the gears seemed to bang harshly. We checked the oil level, which seemed precariously low. It wasn’t bad, but we drained the oil and replaced it with fresh Custom Chrome tranny lube.

 

shovel on lift 500

The 1928 Shovel was ready to rock and so were we. Deacon and Glen broke out harmonicas and kicked off the blues. They sampled the Irish whiskey, Tullamore Dew, Sin Wu barbecued and the party rolled on.

 

playing harmonicas 500
Deacon and Glen bringing down the Bikernet Garage.

 

toast 500
One mo’ shot of Tullamore Dew.

Helluva night, sharp bike and times to always remember. The next day Deacon air-freighted his 2003 FLH to Oahu and grabbed a flight. His son and Amanda boarded their basket case Softail and rode north. Glen and Kerry hid out in Los Angeles and waited for their flight back to Australia, and we dusted off the headquarters and pretended to go back to work.

Stay tuned for the next adventure of the 1928 Shovelhead.

–Bandit

 

deacon thru wheel 500

 

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Bikernet West Bogged Down In Pheonix

I knew it! The sonuvabitch couldn’t make it to the Badlands and back on that piece of shit. I knew it! The way Bandit mounted that tank was fucked from the beginning.

I told him. Nuutboy told him. Harold Pontarelli told him. Shit, his 78-year-old mother told him. Did the big bastard listen? Nooo. So it jumped off the frame in Aspen, Colo., and landed in his lap.

Yeah, they welded it up in Aspen with the help of Randy Aron from Cycle Visions in San Diego, and he limped into Sturgis, rode around the Badlands for the week and then the scoot was kidnapped from him by someone who knows what the fuck he’s doing, namely Paul Yaffe from Paul Yaffe Originals in Phoenix.

Paul is working with Kyle of Independent Tanks, who hand makes steel tanks from heavy 16-gauge material. It’s about time someone grabbed that bike before it exploded into flames and scorched the ornery sonuvabitch.

So we sent that fly-bitten claybrain to Phoenix for a welding lesson and instructions on how to properly mount a gas tank. If he wasn’t such a hasty-witted old fool, he would have put the bike together right the first time.

Here are shots of the existing piece of shit with the new tanks recommended by Paul, who builds some of the most innovative bikes on the planet.

Paul’s philosophy is to manufacture enough custom components to allow his customers to build something without doing a piece-meal job. “Instead of buying fenders from me that don’t fit the other guys’ frame properly and then mount a gas tank from so and so, and nothing fits properly, I want to give the customer half a chance to build a world-class custom on his own.” Paul’s positioning himself, unlike Bandit, to afford customers with frames, plus the fenders, tanks and billet components to match.

Paul began his operation building LED taillight products. Unlike the slob who runs this joint, Paul is a young man of vast energy and talent who could not contain himself building bikes with existing components. He began building his own fenders, air cleaners, frames, etc. The young upstart with the flaming red hair does share one notion with Bandit: “If you’re going to build a new full-custom for a customer, I want the bike to be a reliable runner, of the newest technology, or how can you call it a new bike?” So all of Paul’s bikes are built with Harley-Davidson Twin Cam drive lines. “I use as much Harley stuff as possible,” Paul said. “Plus the factory is going crazy building more new accessories all the time. The selection is growing by leaps and bounds.”

Damn, if I told that lunkhead Bandit once, I told him a thousand times, it’s time to move away from the Evolution shit into the real world of Twin Cams. But that motley-minded minnow is still out in the garage trying to put two Mikuni’s carbs on his ’48 Panhead. If you want to check true customs, built to ride, check Paul’s site http://www.paulyaffeorginals.com

Finally, after much consternation, Bandit succumbed to one of Paul’s buddies, Kyle at Independent Gas Tanks. These are new, contoured tanks and here’s how ya do it right.

Kyle has been building his own line of steel gas tanks for two years. Prior to ’98, he built tanks for Roger Borget for three years and before that he built Porsche 911 race cars. He won’t get near aluminum. “Not with the engine sizes that are bouncing around in these frames,” Kyle said. None of his creations are Mig welded, either. “I only Tig weld my tanks. I’m glad to work with builders and make suggestions.

I’ve hand-built over 1,000 tanks for Harleys, and if told the brand frame, the stretch and rake, I usually know which tank works the best. I can go with one of my six to eight standard styles, or I can design something out of this world. I can make a bike blend into the crowd or stand out anywhere.”

Kyle’s tanks come with mounting straps. Don’t just weld ’em on and go, though. “Depending on how the tank is designed to mount will depend on if the existing tabs will work immediately or need to be modified,” Paul said. In this case, he created some spacers to allow the tank to set on the frame perfectly to capture the look the big bastard wanted, then he cut the tabs and tacked them to the frame. Next he removed the tank and solid tacked the tabs. He put the tank back on and made sure everything was in place. These tanks are handmade and not manufactured with a jig, so no two tanks are alike.

The tabs were finish welded and the tanks shipped to Harold Pontarelli for repaint.

Paul welds everything with Tig because the Argon gas shield makes for a more controlled burn. It gives him better penetration and a less brittle weld than a Mig. Kyle had one other recommendation. He often gets calls from brothers requesting tanks after they have taken their frame to the powdercoater. Don’t do that. Make sure all the sheet metal is prepped and assembled before any finish work is undertaken. In fact, many builders ride scoots without paint for a hundred miles or so before tearing down for paint. Saves the headache, and makes for a much tighter custom.

Of course the whole operation must have a photo finish. Two days before the Love Ride, the tank is floating into town via Harold and eight H-D Performance troopers. The bike is rumbling in on the back of Paul Yaffe’s custom trailer. The two will meet with Bandit in Woodland Hills for the install and road test for the parties to come that weekend. He doesn’t deserve this scoot. It should be mine.

–Renegade

 

 

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Bikernet West – The Chop Lives

 

 

With the final Joker Machine forward controls bolted in place on the Daytec stretch, Bandit began his test ride period. With 300 miles estimated on the machine, a full fluid change took place and only one element was left hanging–the speedometer. For Bandit, trip gauges act as gas gauges. Once he knows the mileage capacity of his tank, he resets his trip gauge to zero at each gas stop and rolls.

 

We plan to back up the shots here with an article on Joker Machine components that went into making this bike the hot shot it is.

Rich, the designer at Joker, who lives in a small air-conditioned cubby hole in the pristine Joker Machine facility, put a great deal of thinking into their components. For instance, their foot pegs have an Allen set screw between the body and the peg to adjust the angle of the peg. So, if your foot is vibrating or sliding off, you can fix the bastard and not suffer. That’s just one of many well-thought-through elements in their components. Besides, they look hot as hell.

  

The speedometer arrived from the Dallas Easyriders with a little over 24 hours to kick-off. The cable was coiled in a cardboard box waiting and the drive unit was already bolted to the front wheel. Unfortunately, the cable was the wrong unit and a hunt began for the proper cap. A call from Phil, the Hamster painter, encouraged Bandit to send a young lady to see Jim at Drag Bike Engineering. He had the cable and, at three in the morning, Bandit was installing it.

We will also follow this series with an article on the Weerd Bros. front ends. This is a ball-milled wide glide that, depending on what ruler you use, is approximately 14-over. According to Bandit, who is in the garage packing as I hit the keys, the front end is light handling with narrowed flat track bars due to the six degrees of additional rake. Even with an overall 44 degrees of rake, the front sliders are smooth and work effortlessly. Although this is a European-built front end with metric Allen head fasteners, it’s highly adjustable with removable fender mounts and brake caliper mounts that can be installed on both lowers or either one or none for the hardcore muthas.

Bandit’s about to take his Blue Flame for a final test ride with his bed roll centered over the Weerd Bros. front end. Yesterday, during the heat of the harbor day, a small Fed Ex package arrived. It was from C.J., the old biker engraver. Inside was a Bikernet engraved point cover, a “Bandit” money clip, and a flamed mag light. When more photography is revealed of the Blue Flame, the Bikernet logo with our babe mascot will be revealed in all her nearly nude glory. Damn, when she walks into the sagging headquarters, everything stops, as if a contact high permeated the garage. In a daze we watch her every fluid move. By reader demand we will post a photograph of the lavish facility in the next couple of weeks.

The bastard is rolling out in the wee hours of the morning and the race will be on for the Badlands. Agent Zebra will be heading out of Miami at noon on Saturday heading north and into Tennessee, as Bandit heads east across the border into Arizona where he will relieve his helmet of duty and ride on in freedom toward Phoenix.

More reports are forthcoming. Live from the Bikernet World Headquarters in San Pedro, California. This is Renegade. Over and out.

 

 

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Sturgis 2000 Project Bike – Bandit II Lives

Each custom motorcycle has a story. That’s one aspect of this treacherous world that sets it apart from stock bikes. Stop any rider of a chop and ask him about his bike and he’ll either punch you in the face or tell you how he started to build his bike, lost his wife and family in the process, and had to sell his home and move into a rented garage in order to complete the project. There’s a story of romance, heartbreak, hard work, and struggle behind any bike. This one is no different.

Now comes another saga, equally terrifying, equally fraught with intrigue and heart. This tale of woe begins five years ago with a project conceived with Ron Simms of Bay Area Custom Choppers. The plan was to build a bike as a tribute to the ’30s. But times changed and attitudes became harsh as the unit came together. The more we worked, the farther the project ventured from the reality of the hard-riding world.

Ultimately, the bike was finished and featured in the February issue of VQ magazine. As a tribute to all who worked on it, we will feature the entire list of talents that it took to complete (…see the partial list of the crew). The sad part of the story is that the bike was ultimately unrideable. Hell, we couldn’t even trailer it to shows without damaging the chassis, and the bike was put up for sale with less than a couple of miles on it.

But we don’t like the idea of selling something that our brothers helped us build and a suggestion was made to turn it into the ultimate ground-pounding, coastal-bar-hopping bastard. We pondered the thought. We kicked around the years it took to build it in its current form, the times we went through, the love that was lost and gained, the adventures, the rides, and the wild times to come. We thought about Sturgis 2000 and what to ride. I spoke to my brothers. We had considered riding old bikes. So the gauntlet was tossed into the ring. Build a rigid flyer from the pieces of the Bandit II and keep it alive, or put dual carbs on a ’48 Panhead and take our time?

Ah, but the Bikernet staff can’t proceed with anything that’s status quo, we’ve got to tear the whole enchilida to the ground and start over, and do it with a vengence. At another meeting at Harold’s dive bar in San Pedro while tossing back stout glasses of Jack, a contest was conjured up. Bikernet East (the chicken-shit Agent Zebra who couldn’t hold a job in Los Angeles and escaped to Miami with his European nymphet) against Bikernet West (Bandit himself, riding a Daytec Rigid). Since the homeless, jobless bastard of Barstow doesn’t have a dime to his name, but still writes vile stories about the upstanding members of Bikernet, we voted to build him a bike to ride to Sturgis. Bandit was already tweeking the drawing board with parts from the Bandit II, hence a contest. Bikernet East rides against Bikernet West to the Badlands and we’ll take a vote as to who has the coolest bike that makes it. Yeah that’s right – gotta make it there to be voted on.


Photo One
As it turns out, we will be able to use the entire driveline from the Bandit II for the Bikernet West rigid chop, including the 98-inch S&S, Simms-built motor (photo 1) and Custom Chrome transmission. It will be placed into one of Daytec’s 4-inch stretched, wide-tire rigid.
The Harley-Davidson narrow glide (photo 2) will stay with the original Paughco frame for the Bikernet East project and a new long front end will grace, perhaps a Weerd Brother glide, the Daytec chassis.
Photo Two

Photo Three
Two Road Wings 60-spoke wheels have been laced and mounted to Avon tires. The front will be a 21 with a 5-inch wide 18 on the rear. And Bandit picked up a Yaffee sidemount license plate/taillight. All the brakes and controls will remain Performance Machine (photo 3).
Harold Ponterilli will paint the reincarnated Bandit II cobalt blue with ’60s metal flake silver flames touched off with white pinstriping. The Bandit II will live to fly through the streets of Long Beach, Pedro, and L.A. And perhaps, if all goes as the Lord of Choppers dictates, across the desert into the Badlands this year.

You’ll see the entire saga unfold on bikernet, good, bad or ugly.

Ride Forever,
–Bandit


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Bikernet East – Zebra’s Chop Unveiled

 When the dust and metal filings settled, the smoke cleared, and the greasy gang of wrenches at the famous Bikernet Garage sobered up, before us stood a gleaming new chopper, complete and ready to break in, save for a few minor tweaks and a seat.

The Zebra entry for the Bikernet ChopOff 2000 was complete. The Great Northern Steamer, scheduled to blast from the Caribbean shores of South Beach, Miami, all the way to the western Badlands of Sturgis, South Dakota, stood shimmering in the Southern California sunshine. A moment of silence occurred naturally. Then Bandit farted.

The Great Northern Steamer is the first complete entry (or virtually so, save for custom seat, a bit more paint, and a few tweaks and adjustments) to come off the steaming chopper assembly line at the Bikernet West garage in San Pedro.

She’s a fast horse, with no bells, no whistles and a low, clean look. This is a true garage chop. Comprised of our favorite parts from our bad-assed vendors who work with us at Bikernet, the Zebra chop should be a joy to ride and not bad on the eyes either. She’ll roll on new Avon rubber, a 21 up front and a 150/16 in the rear, which is as wide as you can go on a stock softy frame without moving swingarms and trannys. We kept her this way because we know a lot of bros don’t have access to zillion-dollar bank accounts and nine-month time periods to re-engineer entire frames. The Zebra chop was purposely built to be an every-man’s chopper—something any of us could build right in our own garage with a bit of determination and hard work. The Avon rubber will be wrapped around newly released Harley-Davidson Thunderstar rims.

The engine is a salty RevTech 88 from Custom Chrome and came out of the box humming like a dragon sitting on a cattle prod. I can’t wait to get past the break-in and give that big horse some oats and see what she’ll do.

Expect me and whatever lucky lass I decide to strap on the back to arrive early in Sturgis this year.

The tranny is a pussy-smooth Baker 6-speed, known for strength (I’m a bit heavy handed on clutches as Bandit is always pointing out) and high-end gearing. I prefer the left lane.

We took the narrow-glide front end off the Bandit II along with the lighthouse-bright Headwinds headlight and slipped it on. I might have Eddie Trotta at Thunder Designs in Ft. Lauderdale, Florida, (where the bike will be received after being shipped from our garage in San Pedro by Ken Gold) throw on a set of wide-glide triple trees. The jury is still out on that one. Eddie and his men will also be in charge of sharp shooting our work, checking for any errors, and handling break-in oversight.

All the wiring was done by our resident electrical genius, Bandit, who spent the better part of his three tours in Vietnam keeping the big guns of his heavy cruiser wired tight and barking day and night.

The handlebars are Cyclesmith and set flat and low, like the horns on the big bulls that periodically tried to hook my guts out when I rodeoed.

Everything hangs off a Ron Paugh special, a Paughco frame, stretched five inches and raked.

She’s got a Harley-Davidson battery.

The pipes are also from the Bandit II and were initially a ThunderHeader system, the header part, which we sliced off. Now it’s a pair of flashing noise downspouts that make the big RevTech 88 sound like God falling down the stairs when you roll it on. Talk about a sound boner. The call of this big bull will swoon any lass who’s not deaf.

The Ride Lo lowering kit actually took the chop a bit too low and we’re planning on having Eddie Trotta’s boys crank it up a few inches so when I load my 220-pound ass on along with a couple hot rod blondes I scoop up from the topless beach in Miami (I’m not kidding, bros, it’s topless, you should visit), the sucker won’t spark all the way to SD.

It’s a chain drive up front, rubber in back. I know everyone says the chains look good in the rear, but they buzz the guts out of my ladies and I’d rather have a 20-year-old, six-foot goddess from Spain on back than a sparkly chain any day. I can do more with the Spaniard when I get to where I’m going, if you get my drift. The oil bag was a complete motherfucker and we re-hung it about as many times as a cattle rustler in Kansas who gets caught on your favorite horse with your old lady thrown over the saddle horn and your best rifle in the scabbard.

Phil Stadden painted the custom front fender and stock Fat Boy rear fender, which we bobbed considerably. The paint job matches the existing burgundy paint on the Paughco frame, which was one of the parts we got back from West Coast Choppers. Still waiting on the others.

I’ll store my gas in a stretched FXR tank that was jerked long by Russ Tom in Seattle.

We have a left mirror, the right seems to be lost in the West Coast Choppers abyss of “missing” parts, so I may have to buy two new mirrors or just run the right side glass.

I will take the German Feminine (we’re a bit on the outs at the moment, so we’ll see how this part goes) up to Eddie Trotta’s Thunder Design in Ft. Lauderdale when the Great Northern Steamer gets in and measure for a seat

and passenger footpegs. I’m going to try to construct a good-looking seat that seats two comfortably, but retains the very low-profile look of the bike we’ve created. The footpegs will probably sit about an inch behind mine, since the German Feminine was born with enough leg to wade in the deep end of the pool.

We may also add a very striking and radical sissybar to keep all of my lovely European sweethearts on the scoot as I cavort about the balmy regions of Miami. At the moment, the highest point on the entire bike sits at about belt loop height and I’d like to keep it that way. But if I have to add a sissybar to keep my ladies from burning their breeches on the twirling rear Avon, then I’ll construct something radical and good looking to throw behind them.

If I can get Bandit away from the Jack and women to actually send one out, I’ll probably also throw one of the very handy and well-designed Bandit Dayrolls up front to hump gear and any small tools.

Thanks to all the bros at Bikernet West who helped wrench together my entry for the Bikernet Chop-Off 2000. Bandit was the master wrench in charge and spent many a thankless hour, welding naked and screaming in the spooky

recesses of the Bikernet garage in San Pedro and deserves a clean clap on the back for a job well done.

I’ll keep you posted as I run the new horse through her break-ins down in the 100-degree heat of Little Havana and blow off that new chop smell.

Hope all you bros out there are getting your scoots ready for the big run and we look forward to blasting north into the Badlands for some serious partying, eating, drinking, and of course loving the ladies in Sturgis.

Now the focus shifts to getting Bandit’s entry completed. His scoot is looking damned good so far and the air wrenches are singing the Bikernet national anthem day and night.

Bandit and I will be arriving on (we hope) the 5th, covered in bug guts and bragging rights to start campaigning for the big vote to see which chop the bros chose as the Bikernet Chop of the Year.

 

Grease up and get your gear, bros, it’s almost time for the big run...

May the best badass win. See you in Sturgis.

Ride hard,
Special Agent Zebra

Bikernet East
 

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Bikernet West – Electronics in a Weekend

 

 

Wiring is the nemesis of man, the puzzle of the best builders, the hornet’s nest of breakdown treachery. Bandit sat for hours drawing a wiring schematic for Agent Zebra’s Softail, only to rip it to shreds and toss it in the trash. He made lists while Sin Wu brewed strong coffee and baked peanut butter cookies. Bandit barked and growled for a couple of days with each run to the marine store for connectors, to the electronics store for switches, to the Custom Chrome catalog for components. The same formula fit his own West Coast entry in the Sturgis Bikernet Chop-Off. We knew as soon as he mentioned that the bike was ready to wire, that we should pack our shit and leave. We took the case of Jack fifths, the girls, and checked into the nearest fleabag motel. While we sat around the stanky pool and partied, Bandit thought about each wire, each connection, and each component.

His mentor, Giggie from Compu-Fire, was his only sounding board and the only sonuvabitch big enough to snap back when Bandit growled about wire gauge or lost connectors. He wired the bike entirely with 14-guage wires. The only other sizes used were for the battery cables (stock units) and the wire that ran from the battery to the ignition switch (12-guage). Even when the sexually starved statuesque Asian roamed into the garage with cocktails, adorned in a sheer negligee, she was ordered back to the headquarters. Soon she found another plaything to keep her occupied, but that’s another story.

Wiring, in the big guy’s mind, is a process of understanding what is happening with each component, where each component is located, watching for the safety of each wire, keeping the bike sanitary, and organizing each group of wires. Each wire is covered with shrink tubing, each connector supported with additional shrink tubing. Each bike had a minimum of wires carefully placed. Each bike had a minimum of components to keep the wiring process uncomplicated or enhance the reliability of the machine. No turn signals, no handlebar controls, and no micro switches. He used only millspec (military specifications) or marine quality switches. Vibration is a killer on motorcycles and much the same on boats, in addition to the moisture considerations. One additional component made wiring simple and risk free, the Custom Cycle Engineering starter mounted mechanical switch. (Check the article here in the Garage.) This unit eliminated the starter button, the starter relay, and all the associated wires. You must make sure you will have access to the switch, which is mounted directly on the starter, under the oil bag, (Photo 2) which can easily be interfered with by the position of the exhaust pipes.

 


Photo 2

 

The concept is that you physically push the solenoid into contact with the starter gears and electrically engage the starter.

We chose a Compu-Fire starter from Custom Chrome to kick this 98-inch monster to life. The key thing on fucking up starter motor installation is over tightening the brass lug wire fitting. It may turn the connection on the inside of the starter and ruin the contacts.

Compu-Fire has designed a new line of starters which feature 6:1 gear reduction (Photo 3) and a 6-pole permanent magnet field to eliminate starter stall-out.

 


Photo 3

 

These units deliver maximum cranking torque without overloading the battery. They also eliminate starting problems on fuel injected bikes.

Only two switches were used and one 30-amp H-D (common at any electronic or auto parts store) circuit breaker. One on-off marine toggle for the ignition, which energized the Compu-Fire single-fire ignition system, the hydraulic brake switch, and the taillight. Since all the sweet parts like handlebar controls, foot controls, mirror, and taillight were Joker Machine components, he was in luck. Joker works the brake light switch into the body of forward controls, which eliminated the bulky hydraulic switch, the junction, and a two-piece rear brake line. Another wire went to the other switch, an on-off-on switch for the headlight (high/low beam). Two wires were run from it to the headlight. Daytec does a beautiful job of running guide tubes in the frame to hide the wires. Initially, if you chose to do so when ordering a Daytec frame, you can have two inserts welded to the frame seat post rail for electric box mounting. We ordered the certs for this frame but decided that with the simplified wiring program we could stuff switches and all the wires into the structure of the top motor mount. This was Giggie’s suggestion and Bandit readily agreed (a miracle). With careful measurements the switch holes were drilled with several bits until a 1/2-inch hole for each switch was attained. The only guide hole that the frame was missing was one for the headlight wires, but two wires were run through shrink tubing to the headlight and through a 5/16 hole in the motor mount. One wire was run from one side of the ignition switch to the circuit breaker, another, the 12-guage wire ran to the battery. From the circuit breaker a wire ran to the taillight down another guide hole along with the brake switch wire. From the brake switch another wire ran to the taillight, brake element.

We also used a Compu-Fire regulator, which mounted to the front of the motor. One wire ran from the regulator back to the hot lead on the Compu-Fire starter motor. Bandit used the excess 12-guage wire to run from the battery to the hot side of the ignition switch.

Giggie recommends that you use crimpers designed for Duetch connectors for a solid, vibration-handling connection. Bandit used water resistant connectors from a West Marine store.

After some 20 hours in the garage, Bandit was finally lured into a well warmed King size bed by Sin Wu and her girlfriend Coral as the sun came up, but at that point the bike was ready to be fired to life. The question was, could Bandit be fired to life?

–Wrench

 

 

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