Projects
Basement Shovel
3/25/10
3/25/10
It has been awhile since I have started something new. The Bull is under the car cover for the winter and I have always been interested in bikes. Harleys mainly, but I have had a 5 year fling with a V-twin Super Bike.
This page will be dedicated to the next project of building a bobber (a term used for the original modified bike of the 50"s mainly Brit bikes, BSA, Triumph etc). Not to be confused with a chopper, long front ends and raked necks, bobbers are bikes modified from their original form down to the bare minimum. Bobbed or shortened rear fenders is perhaps where they got their name.
Enough history, if you are reading this you already know what a bobber is. The bike will be a Harley of course with a big cube Shovelhead motor, 3" open belt drive, rigid hardtail frame, springer/girder from end, a solo spring seat and jockey shift. Here is where I will depart from the true bobber theme by replacing the "skinny" rear tire with a 280mm tire and rake the neck either 35 or 38 degs. We will have to see as things progress and I am sure I will make changes as I go along.
Now, in true hand built fashion, I will not just buy a bunch of catalog chrome and bolt it to together (no offense here). The frame will be hand built as well as the front end forks. Yes, I said the front forks. I have plans to hand build a springer front end which was something right off the vintage Harley 45 motorcycle. With modern technology, the suspension of the springer has been vastly improved and will give the bike a totally different look from what the factory has put out.
The theme of this build is to keep it as cheap as possible, hence building the frame and watching e-bay for that great deal. The will be a budget minded build having the look like a fortune was spent on it.
Until finished I will update this page with build tips, ideas and show the process of the project as it progresses. P.S. this will not take 17 yrs......trust me!
Courtesy of Chopperhandbook.com
The guys over at Chopperhandbook have everything you could very need to build your own bike included plans, building tips, and a forum with very knowledgeable people to help out. If you have ever considered building a bike from scratch, do yourself a favor and check them out.
http://chopperhandbook.com/neatstuff/girder.htm
http://chopperhandbook.com/neatstuff/CR-280.pdf
The guys over at Chopperhandbook have everything you could very need to build your own bike included plans, building tips, and a forum with very knowledgeable people to help out. If you have ever considered building a bike from scratch, do yourself a favor and check them out.
http://chopperhandbook.com/neatstuff/girder.htm
http://chopperhandbook.com/neatstuff/CR-280.pdf
3/30/10
Here is my part collection for the build so far. Just happen to score a Dellorto DHLA 40mm carb with a shovelhead manifold. E-bay ($200) These were used as a performance upgrade in the 70's-80's before S&S carbs took over. Perfect for the old school look. These babies are getting hard to find. I used some elbow grease (Mothers) and a trip down the ACE Hardware bolt supply for some S.S. metric capscrews,a rebuild kit off E-bay ($19), carb cleaner and it looks like new. I added a choke lever from a Arctic Cat snowmobile NOS ($8) and some Weber chrome airhorns ($17) Oh these are not for long legs in shorts kind of carbs. They hang out just over your knee.
Found this little jem in my neighbors garage...Softail 21" rim and Dunlop tire from a recent take-off with a good rotor. ($50) We will powder coat that gloss black ($20)
Here is my part collection for the build so far. Just happen to score a Dellorto DHLA 40mm carb with a shovelhead manifold. E-bay ($200) These were used as a performance upgrade in the 70's-80's before S&S carbs took over. Perfect for the old school look. These babies are getting hard to find. I used some elbow grease (Mothers) and a trip down the ACE Hardware bolt supply for some S.S. metric capscrews,a rebuild kit off E-bay ($19), carb cleaner and it looks like new. I added a choke lever from a Arctic Cat snowmobile NOS ($8) and some Weber chrome airhorns ($17) Oh these are not for long legs in shorts kind of carbs. They hang out just over your knee.
Found this little jem in my neighbors garage...Softail 21" rim and Dunlop tire from a recent take-off with a good rotor. ($50) We will powder coat that gloss black ($20)
4/8/10
I have started the frame by fabricating the small brackets and frame tubes required to build a Harley rigid hardtail frame. I downloaded the plans from Chopper handbook (see link) and they show you everything you need to fabricate. I have made pretty good progress and hope to bend up some tubing shortly for the down tubes.
I also located an interesting rear fender off E-bay ($37) which is a retro-bobbed fender with side embossing from the Panhead springer era. I think Drag Specialist original made it but is no longer available. I will have to widen it to fit the 280mm tire but that will come later. Since I will be riding mine, I will add the rear fender unlike the bike pictured at the top of the page (show bike), I will however fore go the front fender in true bobber fashion...
I have started the frame by fabricating the small brackets and frame tubes required to build a Harley rigid hardtail frame. I downloaded the plans from Chopper handbook (see link) and they show you everything you need to fabricate. I have made pretty good progress and hope to bend up some tubing shortly for the down tubes.
I also located an interesting rear fender off E-bay ($37) which is a retro-bobbed fender with side embossing from the Panhead springer era. I think Drag Specialist original made it but is no longer available. I will have to widen it to fit the 280mm tire but that will come later. Since I will be riding mine, I will add the rear fender unlike the bike pictured at the top of the page (show bike), I will however fore go the front fender in true bobber fashion...
4/18/10
Well, I have collected a few more parts for the project and split the fender in half to be widened and dropped it over the tire to see what it might look like. I couldn't wait after getting the tire. Big tire! 285/35/18 ($100). Now I know what some of you are thinking. It's a car tire and you would be right. Before wide tires were available for choppers, car tires were used on some of the first fat tire builds and this is going to be just that old school. It also will loose some of the handling with reduced lean angles but this is not going to be a knee dragger anyway. The fender will require a 6" filler strip welded in.
I also picked up some Indian Chief gas tanks. They are brand new in the raw with the backer plates to be welded in as well as the gas cap bungs and petcocks. It allows for some custom work without chopping up used tanks and besides I got them for $30/side. What a deal. I have being using some pin stripe tape to see what a trim might look like. I lot of mocking up needs to be done at this stage of the project as it will perhaps influence the design of the frame. Certain things like the motor and trans are pretty much fixed but just about everything else is up to the builder. As much as I would like to see the frame finished, I would be cutting it apart with some changes I have already made.
Well, I have collected a few more parts for the project and split the fender in half to be widened and dropped it over the tire to see what it might look like. I couldn't wait after getting the tire. Big tire! 285/35/18 ($100). Now I know what some of you are thinking. It's a car tire and you would be right. Before wide tires were available for choppers, car tires were used on some of the first fat tire builds and this is going to be just that old school. It also will loose some of the handling with reduced lean angles but this is not going to be a knee dragger anyway. The fender will require a 6" filler strip welded in.
I also picked up some Indian Chief gas tanks. They are brand new in the raw with the backer plates to be welded in as well as the gas cap bungs and petcocks. It allows for some custom work without chopping up used tanks and besides I got them for $30/side. What a deal. I have being using some pin stripe tape to see what a trim might look like. I lot of mocking up needs to be done at this stage of the project as it will perhaps influence the design of the frame. Certain things like the motor and trans are pretty much fixed but just about everything else is up to the builder. As much as I would like to see the frame finished, I would be cutting it apart with some changes I have already made.
4/24/10
A little more work has taken place since last time I posted. I have been working hard on the frame after hours at work and will have to post some pics next week. Until then I have the fender tacked together with the filler strip and ran it through the English wheel to put some of the curve back into the top as not to look like a fat trailer fender. I mocked up a fender trim with some paper to be made out of S.S. and contoured to fit the curve just right and a 1/4" S.S round stock welded just under the edge to give it some depth. It will be polished but not chromed. There will be minimal chrome here. Not because of the expenses but strictly for the effect.
A little more work has taken place since last time I posted. I have been working hard on the frame after hours at work and will have to post some pics next week. Until then I have the fender tacked together with the filler strip and ran it through the English wheel to put some of the curve back into the top as not to look like a fat trailer fender. I mocked up a fender trim with some paper to be made out of S.S. and contoured to fit the curve just right and a 1/4" S.S round stock welded just under the edge to give it some depth. It will be polished but not chromed. There will be minimal chrome here. Not because of the expenses but strictly for the effect.
4/28/10
Here is the frame going together. I made a quick flat surface out of some ground surface plates and an old die cart. With a little shimming it was as flat as I could have hoped for. This was put together for a one time deal so everything was just tacked together and will be discarded (maybe I should put it back where I found it!) One tool I found to be very valuable is a digital angle finder. It helps keep the tubes at the angle they should be while bending and the neck angle correct. Hmmmm, I thought it was going to be 37 degs...
Total in materials. $160 worth of 1.25 x .065 DOM tubing.
Here is the frame going together. I made a quick flat surface out of some ground surface plates and an old die cart. With a little shimming it was as flat as I could have hoped for. This was put together for a one time deal so everything was just tacked together and will be discarded (maybe I should put it back where I found it!) One tool I found to be very valuable is a digital angle finder. It helps keep the tubes at the angle they should be while bending and the neck angle correct. Hmmmm, I thought it was going to be 37 degs...
Total in materials. $160 worth of 1.25 x .065 DOM tubing.
5/5/10
I managed to get the down tubes made to the correct angle and both the same but the real challenge was to get them fitted to the neck tube. 4 hours went into grinding them to fit perfect. One thing you don't want is a weld joint with big gaps to try and bridge with weld makes for a weak joint. This is not the place to have a poor weld going down the road.
I fitted the fender just to see how it looks. Holy massive Batman! It is taking on the drag bike look just like the bike that inspired me to start this whole project. The Indian gas tank backer is used to mock up the look of the tank and the shape of the backbone. This will be my next chanllenge to curve a piece of 1.5" DOM tubing to match that profile...next time.
I managed to get the down tubes made to the correct angle and both the same but the real challenge was to get them fitted to the neck tube. 4 hours went into grinding them to fit perfect. One thing you don't want is a weld joint with big gaps to try and bridge with weld makes for a weak joint. This is not the place to have a poor weld going down the road.
I fitted the fender just to see how it looks. Holy massive Batman! It is taking on the drag bike look just like the bike that inspired me to start this whole project. The Indian gas tank backer is used to mock up the look of the tank and the shape of the backbone. This will be my next chanllenge to curve a piece of 1.5" DOM tubing to match that profile...next time.
5/21/10
I have been working on the backbone of the frame so it follows the shape of the tanks and have had some problems making it in one piece. I trash canned the first attempt when the tube kinked a little. Since it shows running between the tanks I decided to try it again with a little heat from the torch and not be too aggressive this time.
On another front my wheels have come in from the rim maker, all powder coated black with polished SS spokes. Are you thinking what I am thinking? Pretty wide huh! Heavy too since they are steel. At 10.5" I see why choppers go with aluminum billet. I wanted spokes for the look but never thought of the weight. I guess I might have to rethink the Shovelhead motor and think about a big stroke EVO. Maybe 127" to push this heavy weight around.
Found some forward controls at a swap meet for $50. Another deal.
I have been working on the backbone of the frame so it follows the shape of the tanks and have had some problems making it in one piece. I trash canned the first attempt when the tube kinked a little. Since it shows running between the tanks I decided to try it again with a little heat from the torch and not be too aggressive this time.
On another front my wheels have come in from the rim maker, all powder coated black with polished SS spokes. Are you thinking what I am thinking? Pretty wide huh! Heavy too since they are steel. At 10.5" I see why choppers go with aluminum billet. I wanted spokes for the look but never thought of the weight. I guess I might have to rethink the Shovelhead motor and think about a big stroke EVO. Maybe 127" to push this heavy weight around.
Found some forward controls at a swap meet for $50. Another deal.
6/3/10
It has been a little while since I posted any progress on the bike. I lot has happened and a surprise came in that I am being sponsored to bring the Bull to the Sturgis Bike Rally this Aug. I was also asked to bring the bike project as a part of a theme of metal crafting seminars under one large tent with some pretty good talent showcasing their DIY projects. I am honored and have tried to step the bike project up a notch to meet the deadline. You will notice the seating area is getting a little crowded with the big engine bay and no stretch in the backbone. A custom made seat might need to be made but until I mount the rear wheel and fender, I will not no for sure. That is my next goal....
It has been a little while since I posted any progress on the bike. I lot has happened and a surprise came in that I am being sponsored to bring the Bull to the Sturgis Bike Rally this Aug. I was also asked to bring the bike project as a part of a theme of metal crafting seminars under one large tent with some pretty good talent showcasing their DIY projects. I am honored and have tried to step the bike project up a notch to meet the deadline. You will notice the seating area is getting a little crowded with the big engine bay and no stretch in the backbone. A custom made seat might need to be made but until I mount the rear wheel and fender, I will not no for sure. That is my next goal....
6/18/10
Finally some more progress. I tig welded all of the joints on the frame and I was very happy the way they turned out. I guess I still have it...steady hand! The idea was to not grind the welds and leave them just they way they were made. I also have the tire mounted on the rim and looking to position the fender with some hand made fender struts off the axle plates. I mocked up a seat pan and with some springs it will ride like my Farmall M tractor. I can only hope. My lower back is not what it used to be.
You will notice on my home page I mention I am being sponsored to be at the Sturgis Bike Rally with the Bull and this bike project. I will have Eddy Trotta ( Biker Build Off ) looking over my work and it is making me a little nervous. I have never built a bike like this. What do you think?
Finally some more progress. I tig welded all of the joints on the frame and I was very happy the way they turned out. I guess I still have it...steady hand! The idea was to not grind the welds and leave them just they way they were made. I also have the tire mounted on the rim and looking to position the fender with some hand made fender struts off the axle plates. I mocked up a seat pan and with some springs it will ride like my Farmall M tractor. I can only hope. My lower back is not what it used to be.
You will notice on my home page I mention I am being sponsored to be at the Sturgis Bike Rally with the Bull and this bike project. I will have Eddy Trotta ( Biker Build Off ) looking over my work and it is making me a little nervous. I have never built a bike like this. What do you think?
6/29/10
Progress has been slow with having to make so many brackets and mounting tabs but I see the light at the end of the tunnel...being able to sit on both tires. The oil tank was mounted when it hit me maybe I was locking it in with my direct mounts while Harley used a two piece bracket. I decided I needed to weld up the mounting complete after tacking them in using the oil tank itself for locating them. Well the funny thing is, chrome has a funny way of getting away from you when it still has that slight oil film on it. You guessed it. The mounts didn't lock it in as it hit the floor but not before kissing the front square on my set-up table. $50 mistake...I don't like chrome anyway and had intentions of painting at some point but I don't have time now. E-bay????
The tank shells are mounted old school with rubber mounts over the top back bone. Again all made by hand. Some bronze bearing material and $.80 grommets and straps of S.S. formed on the rod former. I found it has a brake die for forming 90's on flat stock. Is there anything you can't do with one of these things?
I think I should name this bike Igor after showing it to the wife. She asking "Why the hump at the front of the tank"? I said it has a hump back..it wasn't planned that way either. The back bone got so high following the tank profile that it needed to nose drive back to the steering neck without getting in the way of the triple trees. Funny how those things happen when building something from scratch. I will just let it grow on me...no pun intended!!!!!!!
Progress has been slow with having to make so many brackets and mounting tabs but I see the light at the end of the tunnel...being able to sit on both tires. The oil tank was mounted when it hit me maybe I was locking it in with my direct mounts while Harley used a two piece bracket. I decided I needed to weld up the mounting complete after tacking them in using the oil tank itself for locating them. Well the funny thing is, chrome has a funny way of getting away from you when it still has that slight oil film on it. You guessed it. The mounts didn't lock it in as it hit the floor but not before kissing the front square on my set-up table. $50 mistake...I don't like chrome anyway and had intentions of painting at some point but I don't have time now. E-bay????
The tank shells are mounted old school with rubber mounts over the top back bone. Again all made by hand. Some bronze bearing material and $.80 grommets and straps of S.S. formed on the rod former. I found it has a brake die for forming 90's on flat stock. Is there anything you can't do with one of these things?
I think I should name this bike Igor after showing it to the wife. She asking "Why the hump at the front of the tank"? I said it has a hump back..it wasn't planned that way either. The back bone got so high following the tank profile that it needed to nose drive back to the steering neck without getting in the way of the triple trees. Funny how those things happen when building something from scratch. I will just let it grow on me...no pun intended!!!!!!!
7/11/10
It has been almost 4 months since I started this project and the goal was to have a roller by summer. I didn't know I was going to be showing it at Sturgis when I started it. I have only one thing to finish and that being the spring seat. It is made but needs to be mounted. The idea was to build the bike by hand as much as I could without buying everything. I have stuck to the plan but almost gave in out of shear time and bought the seat and handle bars. Some how it seemed wrong to do with everything having the handmade look. Sat. I spent the whole day designing the handle bars and welding them up. I also welded up the springer front end which was handmade as well. The springs and hardware were the only things purchased. I hope you like how it turned out. We will see how the crowd at Sturgis reacts to it. I will let you know when I return. Aug 9th-15th.
It has been almost 4 months since I started this project and the goal was to have a roller by summer. I didn't know I was going to be showing it at Sturgis when I started it. I have only one thing to finish and that being the spring seat. It is made but needs to be mounted. The idea was to build the bike by hand as much as I could without buying everything. I have stuck to the plan but almost gave in out of shear time and bought the seat and handle bars. Some how it seemed wrong to do with everything having the handmade look. Sat. I spent the whole day designing the handle bars and welding them up. I also welded up the springer front end which was handmade as well. The springs and hardware were the only things purchased. I hope you like how it turned out. We will see how the crowd at Sturgis reacts to it. I will let you know when I return. Aug 9th-15th.
7/25
It's less than two weeks until the Sturgis Motorcycle Rally and the rolling bike is finished. It took a little more work than I first thought and now I understand why a roller can cost in the neighborhood of $4500 and up. Now I have only $1100 in mine mostly in the wheels and tires but a lot of after hours in labor and smart shopping on E-bay. Some of that labor is in the design where I parted from the standard hardtail and went a little down my own path. The arched backbone being one and the car tire! It is one of the beautiful things about building a bike, the personal flare in its design. There is no right or wrong way to layout a bike as along as its owner is pleased with it and it functions to a degree....again it is the perception of its owner what he or she can live with that will push the envelope.
Anyway, I didn't push the envelope by any means and I hope you enjoyed watching it come together. Next time I will have returned from Sturgis, I give you a taste of what it is like being there as an exhibitor and how well the Bull and the Bike were received..
It's less than two weeks until the Sturgis Motorcycle Rally and the rolling bike is finished. It took a little more work than I first thought and now I understand why a roller can cost in the neighborhood of $4500 and up. Now I have only $1100 in mine mostly in the wheels and tires but a lot of after hours in labor and smart shopping on E-bay. Some of that labor is in the design where I parted from the standard hardtail and went a little down my own path. The arched backbone being one and the car tire! It is one of the beautiful things about building a bike, the personal flare in its design. There is no right or wrong way to layout a bike as along as its owner is pleased with it and it functions to a degree....again it is the perception of its owner what he or she can live with that will push the envelope.
Anyway, I didn't push the envelope by any means and I hope you enjoyed watching it come together. Next time I will have returned from Sturgis, I give you a taste of what it is like being there as an exhibitor and how well the Bull and the Bike were received..
