I get tired of talking about the 2008 economic downturn and how it devastated the motorcycle, sailing, and many other industries. I wish I could say we are cured and walking proudly down the yellow brick road to metalflake Nirvana. It just ain’t so. But there is hope and there are quality American companies trying to do their utmost to keep us on the road to bobbed or chopper freedom.
There is still one custom chopper manufacturing facility still standing, maybe three. One in particular, Brass Balls Cycles or Darwin Motorcycles, recently launched a kit bike program and made it ultimately affordable. They are not a parts company trying to unload a batch of out-of-stock components or junk. Dar Holdsworth builds quality custom motorcycles everyday. He builds and restores motorcycles every year to support Pros4Vets. He saw the need to help guys ride their dream machines without the expense of hiring someone to build it. Besides, no one understands the desire to build bikes more than Dar.
He started a kit program with the quality components he uses on his own builds. He tried to structure it so that a guy could pick his budget and stay within the numbers, which meant he offered some components not made in America, but it’s purely the customer’s decision. He or she can build a 100 percent American component bike, or 90 percent. No problem.
In the near future, each kit will include a Wolfgang publication book on how to build a kit bike, and Dar initiated a program for staying in touch with his customers and supporting them throughout the build process. I’ve built bikes for 40 years, and every time I build a new custom, I have questions or concerns. I always reach out for answers, but I’m a pushy bastard. Dar set up an active support group and is building an advisory board out of customers who have completed Brass Balls builds. See his letter to a recent customer.
James,
Hi there. I hope this finds you doing well.
The reason for my email is to thank you for your business and ask you for your help.
I’d like to ask you to be an honorary member of our Bike Kit Advisory Board.
In reflection, I know we can do a better job with our bike kits. But rather than take an educated guess at it, I’d like to get direct input from a select group of customers who have purchased a bike kit from us and completed it.
I’m not looking for accolades here. I’m looking for your suggestions for what we could do better. Yes, I’d also like to know what we did well, so we can keep doing those things. But I’d like to improve where possible, anywhere from the selection process on our web site, to product delivery and even assistance with the assembly of the bike.
Thank you in advance for taking the time to give your input. I’m preparing a small care package to send you in the mail. Please confirm for me your address and shirt/hat sizes.
I’d also like to feature your bike on our site and in social media. Please email some good photos that we can use and give you credit on a great build.
All the best for a great holiday season.
–Dar Holdsworth
Brass Balls Kit Doctor
Hi Dar
It’s been a great year of riding the new bobber. I’m happy to help you out, but hate to criticize when you supplied such an awesome kit.
There were a few things that could have made the process a bit more streamlined.
I was a bit apprehensive about the wiring of the bike and whether I needed to individually fuse each circuit, or if the Wire Plus module would take care of it. I did get a schematic of an early ‘90s FX from Doug Lyle (Brass Balls staff member) on how to complete the wiring. Would be a bonus to include a wiring diagram along with the wiring harness.
Getting some of the parts across the boarder into Canada was a bit nerve-racking. Although I did have the bill of sale and the itemized list of all the kit parts, there were a couple of shipments that I had to put a packing slip with prices together so that I had something to show Canadian Customs when coming across the border. The next kit will need to have itemized and priced packing slips included so it will be easier to bring the parts across.
The only infant failure I had with the parts was the voltage regulator, which was replaced under warranty.
As far as the website ordering…everything was great on there. After I made the order, it didn’t take very long to get a reply and start getting into some fine detail through e-mail.
–James Lintott
Okanagan Falls, BC, Canada
This level of feedback is critical moving forward and gives the Brass Balls team the ability to refine their program.
There are two basic programs. You can build the bike of your dreams in payment stages, which allow you to purchase the system in phases, not all at once. Or you can buy a complete kit. These kits come with a wide variety of styles and components, so you can basically style your bike around your budget, your size, your riding abilities, and your chopper desires, from rigid, to Softail, or even FXR.
Here’s how the phase system works step by step:
Phase 1: Rolling Chassis
Through many years of building custom/production award winning bikes, we’ve learned which parts have the quality needed to build a safe and lasting bike. We offer these components to you in our bike kits, and from budget minded parts to the highest grade specialty parts, the quality is there.
The core of your bike is the frame. We offer you the same frames we use to build our Brass Balls Cycles line of bikes. All of our frames are to exacting standards and hand made in the USA.
Determine what you want your bike to look like. Select the frame that’s right for you. Choose from a rigid or Softail frame, a springer or hydraulic front end, size and style of wheels, handlebars and risers and you’re off to a great start on the foundation of your dream machine.
Phase 1: Rolling Chassis
Starting at $2,860
Frame: Standard Frame 34 degrees 0 stretch up, or out
Front End: Springer: Black
Front Wheel size: 21-inch x 2.15 (90mm tire)
Rear Wheel size: 16-inch x 3.5 (140mm tire)
Front wheel: RideWright Wheels chrome 40 spoke
Rear wheel: RideWright Wheels chrome 40 spoke
Front Tire: Avon Cobras: 90mm/21 black wall tire
Rear Tire: Avon Cobras: 140mm/16 black wall tire
Handle Bars: Drag bars
Risers: 4-inch tall risers, chrome
Rear Sprocket
Rear axle
Axle adjuster bolts
Kickstand
Head Bearings Tapered
Head Bearing Races
Dust shield
Neck cups
When you go to the Brass Balls web site, you will have a menu listing all the options for each part category.
Phase 2: Sheet Metal and Accessories
Your bike is starting to take shape. Choose from five different fuel tank options we use to build our Model 1 and Digger, Classic Bobber, Rocketeer, 69 Chopper and Vintage American bikes.
Choose a custom gas cap, perhaps a different oil tank or seat springs. Did you select a wider tire in Phase 1? If so, don’t forget a wider fender option in Phase 2. Have fun with it.
Phase 2: Sheet Metal & Accessories
Starting at $997
Fuel tank: Flat side sporty 2.4 gallon
Gas cap: Traditional round low profile: Chrome
Petcock fuel valve: chrome
Oil tank: Flat side round w/battery tray: raw
Rear Fender: 6.5” for 140mm tire fitment. Stamped fender, untrimmed
Seat: Traditional Seat Springs
Heavy Duty isolators for oil tank
Oil tank rear bracket front & rear brackets
Oil tank drain plug
Oil tank hose nipples
Fuel filter, chrome
Fender struts kit (not welded)
Seat Pivot hinge and mount
Seat Springs
Darwin Motorcycles Tag bracket w/LED light
Phase 3: Brakes & Controls
Controlling your bike is vital. You need solid controls that work as good as they look and feel like an extension of yourself.
You also have the option of different foot controls, hand controls and grips. The ISR hand controls are incredible, and if you are inclined to use the best, don’t pass them up. If you want clean understated switch housings, the ISR housings again are our preferred choice. Contact us for help selecting which switch housings are best for your bike.
Phase 3: Brakes & Controls
Starting at $1,557
Brakes Front Wheel: Wilwood GP300 caliper for springer w/Brass Balls hanger: polished
Brakes Rear Wheel: Wilwood GP300 caliper, polished w/hanger
Foot Controls: Foot Controls – Chrome
Hand Controls: Black: Master Cylinder, brake lever & Clutch lever (cable style)
Grips: Avon old school rubber, black
Signals and Switch Housings: None. No Switch housings or signal switches
Brake Banjo Fitting, 45 degree (2 each)
Brake Banjo Fitting, 15 degree (2 each)
Brake hose #3, 30-inch front, and 40-inch rear
Brake Banjo Bolt 10mm 3/8 – 24 (2 each)
Brake Switch (2 each)
Brake Switch Boot (2 each)
Motion Pro Throttle Cable 32.5-inch black
Motion Pro Idle Cable 32.5-inch black
Motion Pro Clutch Cable 62.75-inch black
Brake Heim joint assembly, front
Brake Rotor Front, Satin
Brake Rotor Rear, Satin
Throttle housing
Cable clamp
Mirrors
Phase 4: Powertrain
The heart and soul of your bike is the powertrain. Choose it wisely.
The motor you put in your bike speaks to your personality and riding style. Is it power you want or vintage style? Are you looking for a motor that provides the “best bang for your buck,” or do you want a motor built by a company with a 55-year heritage of building performance quality V-Twins?
We have a sharp selection of primary drives to choose from, including enclosed (wet) chain drives and open belt drive options.
If you want a strong transmission at a great value, we strongly suggest Rivera Primo. It’s what we use in all of our Brass Balls Cycles.
Pipes can be tricky. Different motors require different pipes. We are here to help you get the right pipes for your bike.
Phase 4: Powertrain
Starting at $6,985
Motor: Ultima: 107-inch Natural w/ Chrome Rocker Boxes
Motor Finish: Natural
Motor certification: none
Transmission: Ultima 6-speed: natural w/chrome covers
Primary Drive: Ultima 2-inch Belt Drive, Old School: Natural
Exhaust Pipes: D&D Performance Brass Balls 2 into 1 Fat Slash
Exhaust Pipes Finish: Raw metal
Offset Transmission sprocket .9-inch
Transmission sprocket nut & washer
Clutch Push Rod
O-ring chain
Chain Guard
Oil Filter
Oil Filter Mount
3/8-inch Fuel Oil Hose
Throttle Cable Guide
Line Clamps
Upper Motor Mount w/Coil Bracket
Exhaust Gaskets (2 each)
Drivetrain Hardware
Rear Spacer .500
14” Polished Shift Linkage
Coil, Single Fire
Spark Plug Wires
Phase 5: Electrical
Our base kit includes an All Balls starter, Braille battery, Cycle Electric charging system, a Wire Plus custom wire harness designed by us for our bikes, in addition to other quality components.
Phase 5: Electrical
Starting at $1,420
Starter: Starter 1.4 KW top post (All Balls)
Headlight: Bobber headlight Chrome 5-3/4-inch w/mount & 12V halogen bulb
Tail Lights: Lighting, Turn Signal Kit (set of 4)
Ignition Key Switch
Battery Wire
Battery Terminal ¼-inch
Battery Terminal 5/16-inch
Fuse and Holder, 30A
Voltage Regulator 32 amp (Cycle Electric)
Stator, 32 amp
Rotor (internal)
Battery Braille 2015
Battery Cushion
Battery Cable/Starter Post Boot
1/4, 3/8, 1/2, & 1-inch dual wall
Brass Balls Wiring Harness
Horn, Mini, chrome
Battery Strap
This system allows you to start a world class bobbed project and build it as the funds become available.
STOP! There’s more. Yes, you can buy a complete bike kit all at once, starting at $13,000.
All Five Phases: Bike Kit
Starting at $13,819
Frame: Standard Frame 34 degrees 0 up, 0-inch out
Front End: Springer: Black
Front Wheel size: 21-inch x 2.15 (90mm tire)
Rear Wheel size: 16-inch x 3.5 (140mm tire)
Front wheel: RideWright Wheels chrome 40 spoke
Rear wheel: RideWright Wheels chrome 40 spoke
Front Tire: Avon Cobras: 90mm/21 black wall tire
Rear Tire: Avon Cobras: 140mm/16 black wall tire
Handle Bars: Drag bars
Risers: 4-inch tall risers, chrome
Rear Sprocket
Rear axle
Axle adjuster bolts
Kickstand
Head Bearings Tapered
Head Bearing Races
Dust shield
Neck cups
Fuel tank: Flat side sporty 2.4 gallon
Gas cap: Traditional round low profile: Chrome
Petcock fuel valve: chrome
Oil tank: Flat side round w/battery tray: raw
Rear Fender: 6.5-inch for 140mm tire fitment. Stamped fender, untrimmed
Seat: Traditional Seat Springs
Heavy Duty isolators for oil tank
Oil tank rear bracket front & rear brackets
Oil tank drain plug
Oil tank hose nipples
Fuel filter, chrome
Fender struts kit (not welded)
Seat Pivot hinge and mount
Seat Springs
Darwin Motorcycles Tag bracket w/LED light
Brakes Front Wheel: Wilwood GP300 caliper for springer w/Brass Balls hanger: polished
Brakes Rear Wheel: Wilwood GP300 caliper, polished w/hanger
Foot Controls: Foot Controls – Chrome
Hand Controls: Black: Master Cylinder, brake lever & Clutch lever (cable style)
Grips: Avon old school rubber, black
Signals and Switch Housings: None. No Switch housings or signal switches
Cable clamp
Mirrors
Brake Banjo Fitting, 45 degree (2 each)
Brake Banjo Fitting, 15 degree (2 each)
Brake hose #3, 30-inch front, 40-inch rear
Brake Banjo Bolt 10mm 3/8 – 24 (2 each)
Brake Switch (2 each)
Brake Switch Boot (2 each)
Motion Pro Throttle Cable 32.5-inch black
Motion Pro Idle Cable 32.5-inch black
Motion Pro Clutch Cable 62.75-inch black
Brake Heim joint assembly, front
Brake Rotor Front, Satin
Brake Rotor Rear, Satin
Throttle housing
Motor: Ultima: 107-inch Natural w/ Chrome Rocker Boxes
Motor Finish: Natural
Motor certification: none
Transmission: Ultima 6-speed: natural w/chrome covers
Primary Drive: Ultima 2-inch Belt Drive, Old School: Natural
Exhaust Pipes: D&D Performance Brass Balls 2 into 1 Fat Slash
Exhaust Pipes Finish: Raw metal
Line Clamps
Upper Motor Mount w/Coil Bracket
Exhaust Gaskets (2 each)
Drivetrain Hardware
Rear Spacer .500
14-inch Polished Shift Linkage
Coil, Single Fire
Spark Plug Wires
Offset Transmission sprocket .9-inch
Transmission sprocket nut & washer
Clutch Push Rod
O-ring chain
Chain Guard
Oil Filter
Oil Filter Mount
3/8-inch Fuel Oil Hose
Throttle Cable Guide
Starter: Starter 1.4 KW top post (All Balls)
Speedometer: Mechanical speedo with 2:1 drive unit
Headlight: Bobber headlight Chrome 5-3/4-inch w/mount & 12V halogen bulb
Tail Lights: Lighting, Turn Signal Kit (set of 4)
Ignition Key Switch
Battery Wire
Battery Terminal ¼-inch
Battery Terminal 5/16-inch
Fuse and Holder, 30A
Voltage Regulator 32 amp (Cycle Electric)
Stator, 32 amp
Rotor (internal)
Battery Braille 2015
Battery Cushion
Battery Cable/Starter Post Boot
1/4, 3/8, 1/2, & 1-inch dual wall
Brass Balls Wiring Harness
Horn, Mini, chrome
Battery Strap
Bracket for Ignition Switch
