I latest motorbike project is a chopper style for my friend Dave. He's a Harley rider and Insisted on spring fork, sissy bar, ape hangers and fishtail exhaust. I was able to incorporate most of what he wanted. We used a 1962 Schwinn bike I gave him a few decades ago and fitted it with a 5hp Briggs motor. Each new bike I build, I like to try new stuff. I told him you couldn't use a bicycle seat with a sissy bar and I wasn't going to use a banana, so I formed a steel platform with a wooden base and rebond foam cushion. We cut up one of his old Harley leather jackets and had a guy I know upholster it.
Then I fabricated a kickstart mechanism. It took some engineering and trial and error but came out real nice and works great.
Then I wanted to make a tank shifter, so I fabbed up some parts and linked it to the magneto and used it for variable timing.
I also used a 3D Motorsports clutch and mounted it right into the seat down tube.
I adapted a larger flywheel onto it for a smoother running engine and nicer idle. It also helped with kickstarting and taking off. Then I trimmed a Harley air filter cover to fit the flywheel.
I wanted a primary belt cover to resemble an old knuckle or panhead so I made a wooden buck and Dave knew someone who could vacuum form chrome plastic over it. It's about 2/3 scale and looks killer.
Still needs a fishtail, but we're not done.
Then I fabricated a kickstart mechanism. It took some engineering and trial and error but came out real nice and works great.
Then I wanted to make a tank shifter, so I fabbed up some parts and linked it to the magneto and used it for variable timing.
I also used a 3D Motorsports clutch and mounted it right into the seat down tube.
I adapted a larger flywheel onto it for a smoother running engine and nicer idle. It also helped with kickstarting and taking off. Then I trimmed a Harley air filter cover to fit the flywheel.
I wanted a primary belt cover to resemble an old knuckle or panhead so I made a wooden buck and Dave knew someone who could vacuum form chrome plastic over it. It's about 2/3 scale and looks killer.
Still needs a fishtail, but we're not done.
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