rigid frame - Chopper and Punk Rock

The RIGID FRAME motorcycle
The RIGID FRAME motorcycle
JIMS NEW
FLYWHEELS
VOL. 2
No.1
HOW TO INSTALL
HOW TO INSTALL
KNUCKLEHEAD
KNUCKLEHEAD
No.1
BRUTE IV
BRUTE IV
CHOPPER
4A=@AHI
41/1,41,-5
JIMS NEW
FLYWHEELS
VOL. 2
THE 70’S
ARE BACK!!
$3.95 USA
$4.95 CAN
CHROME PONY
MARKETING
FALL 1999
CHOPPER
4A=@AHI
41/1,41,-5
THE 70’S
ARE BACK!!
$3.95 USA
$4.95 CAN
CHROME PONY
MARKETING
FALL 1999
VOL 2
January-February 2000
NO. 1
EDITORIAL
As I perused a popular motorcycle magazine’s ad
rates I read the promo-statement on the jacket. It
claims the magazine is written exclusively for the “new
breed of rider.” What exactly is this “new breed” and
how do we recognize them, so we can gawk. Hey, I
got the answer!! This “new breed” of rider is a rider
that thinks he must have more billet aluminum geegaws on his motorcycle than any other motorcycle in
any garage anywhere. This “new breed” of rider must
positively own a trailer (I do) but not to rescue his broken motorcycle from the side of the road, but to transport his motorcycle to all the events a “new breed”
rider must attend (they wanna ride the bike at the
event, not “TO” the event. I digress, please excuse me.
Are we there yet? Hardtail Magazine is going
places…. I hope. Like all over the country to photograph your rigid frame motorcycles whenever and
wherever possible.We know there are more rigids on
the East Coast than there are in the West. We just
gotta get over there to shoot’em (with a camera of
course) We're looking for all types of rigid frame
motorcycles from choppers to Classics, rats to outrageous, but they gotta be rigid. They also gotta be ridden more than once week, more than 5 miles. One of
today's major MC magazine makes a point of showing
their feature bikes being ridden, this proves the bikes
is ridable, but the photos usually demonstrate how
infrequently the machine is actually ridden any distance. One can see by the look on the riders face,
and/or usually by the way they’re dressed. These
aren’t riders, they’re posers, at least 99% of the time
anyway. A well-ridden motorcycle displays many clues
proving how much road time is on the clock. The
appearance of owner/rider is the first clue. Sunburnt
or brown-weathered face, creases with high mileage
lines. Even younger riders have older looking skin.
Farmer-tan glove lines on the upper side of the hand
is a dead giveaway that these are rider’s hands.
Chipped paint, road-tar, and almost permanent bug
juice are also clues. If a bike is ridden daily, it can't
possibly be immaculate 100% of the time. If you ride
rigid, and your motorcycle looks like the bike on these
pages you may be riding a Hardtail Magazine feature
bike, we wanna see it. Even if your machine is not
usable as a feature bike, we want your pictures for
Readers Rigid Rides, which will be a regular department as we get enough photos. Send us photos, and
letters. And remember, if it has a radio, a radiator, a
windshield, and cruise control, it's not a motorcycle,
IT'S A CAR!
HARDTAIL Magazine
PUBLISHERs
Buck & Traci Lovell
EDITORial director
Buck Lovell
Assistant ART DIRECTOR
Brett W. Lovell
ADVERTISING
Buck Lovell
PHOTOGRAPHY
Buck Buckle
©1999 CHROME PONY Inc
ALL RIGHTS RESERVED
ADVERTISING
To advertise in HARDTAIL Magazine
contact
Buck Lovell
PMB 389
2621 Green River
Corona, CA 92882-7454
HARDTAIL Magazine is a CHROME PONY publication, and will be published 4 times a year until further notice. All
advertising information can be obtained at the above address &
phone number. Dealer inquiries are welcomed. Shops specializing
in rigid frame motorcycles should contact H A R D TAIL Magazine for special editorial consideration. We are
looking for rigid frame features bikes from all over the USA. If you
would like have your motorcycle considered for publication in
please send H A R D T A I L Magazine correctly
exposed, in focus photos no bigger than 5 X7 to the Editorial
address above, attention Editorial Director Buck Lovell.
1
TABLE OF CONTENTS
Page 10 ........................................... PRECIOUS METAL INDEED, Knucklehead
powered motorcycles are getting fewer and farther between. Harley-Davidson first
OHV V-Twin ushered in the chopper era a long time ago. S&M Cycles Fat
Fendered chopper is ready to ride.
PAGE 20
PAGE36
PAGE 10
Page 14 ........................................... PRIMO BELT DRIVES Brute IV has it all. The
best in performance, the best in quality, the Brute IV can handle all the power your
hot-rod motor can put out. Installation is simple and straight forward, take a look.
Page 20 ........................................... ONE UP, 4 DOWN was constructed by the
rider for the rider. The transmission shift pattern is reversed for harder, faster
upshifting during street acceleration contests (we didn’t say that did we?)
Page 24 ........................................... GROOVY FLYWHEELS from Jims Machine
enhance oil scavenging for less windage and more horsepower. Jims Machine has
become famous for quality and innovation in the American Big-Twin aftermarket.
PAGE 24
page 56
Page 26 ........................................... PURE & SIMPLE is a perfect example of
custom bike building that really is custom. No cookie cutter factory stuff here, Craig
built the bike exactly the way he wanted it, influenced by his riding experience. OK,
he finally went electric start, but pretend you don’t notice!
Page 46 ........................................... FRANKENSTEIN was born in it’s owners
garage, a tradition carried over from the 1950’s. Old-school hardcore chopper is
Frankenstein’s claim to fame, and it hauls-ass too. Shovelheads rule!
Page 46 ........................................... FLOWER POWER the “Prismik” chopper
looks like it fell out of a hippies time machine. Its like looking back into the 1970’s
without the acid. Battery acid that is. Whoops, the exhaust pipes are on the wrong
side.....no they’re on the left side, intentionally. Chica is a chopper freak.
Page 52 ........................................... DAYTEC has a rigid frame for you! From
standard selections to virtually anything you could think of (well almost) Daytec
loves to make it’s customers smile. A few pictures and a phone number, call’em.
page 46
page 26
Departments
SOURCES............................page 4
LETTERS TO HARDTAIL .. page 57 (only one
HARDPARTS...................... page 10
Rigid frame ART ............... page
Rigid Riders ...................... page 56
so far)
Readers are invited to send black and white or color photos (no bigger than 5
X 7) of their Hardtail motorcycles (including bikes with struts) for use in our
Readers Hardtail section (next issue), but please, absolutely no photos of
motorcycles with rear suspension of any kind!!
2
PAGE 14
3
3
Hard-Tail Hardparts
DRAG SPECIALTIES
CHROME TRIPLE TREE
ASSEMBLY
NEW PRODUCTS & ACCESSORIES FOR RIGID FRAME MOTORCYCLES
HOT MATCH
kick STANDs
UP AGAINST THE WALL!
New from Hot Match, these high-class, show-chromed
kick-stands are the icing on the cake for any custom or
hot-rod Harley-Davidson motorcycle. An old idea made
more simple, an internal ball & spring that cannot stretch
or break keeps the stand in place. The hidden spring
makes this the cleanest kick stand on the market. A kick
stand must be also strong and reliable, as well as attractive, this kick stand is manufactured from 100% billet steel.
American craftsmanship, super heavy duty construction,
and show chrome make this side-stand a real standout.
Straight or bent style legs are available with either “bolt-on”
for Softail or “weld-on” for custom bikes. The bolt-on unit
attaches at the rear of the Softail frame( drilling and tapping required). Retail price $199.95, dealer inquiries welcome. For all further information see your local Hot Match
Custom Cycles dealer or contact us direct at:
Hot Match Custom Cycles
2548 E. Fender Ave
Fullerton, CA 92831
(714) 680-4362 FAX (714) 680-3874
Voice (714) 205 9826
Hang it on the wall and call it art, this wing-set wall-hanging with removable miniature Flathead, Knucklehead Panhead, Shovelhead and Evo
motors (with magnetic backs. Any red-blooded American motorcycle rider
would love to receive one of these for a Christmas present wouldn’t ya
think? It’s just one of many original motorcycle art works from the creative
mind of John Zambini. Giv'em a call.
zAMBINI Bros
3027 Loma Riviera Drive
San Diego, CA 92110
phone/fax (619) 226 0202
email dgouleti@home.com
DRAGON EL GRANDE
RIGID FRAME
from WEST COAST CHOPPERS
Jesse James is raising the stakes in high-quality, high performance rigid frame styling, design and construction with the
“Dragon El Grande” rigid frame. This is a real chopper frame
manufactured with modern construction methods and materials.
Made to accept a Peanut style gas tank, spun aluminum cylindrical oil tank, and endowed with hidden axle adjusters & fork stops,
you can build a clean, lean chopper machine just like they did
way back when. West Coast Choppers strutless rear fender is
also part of the chopper styling. 37 degrees of neck rake, a 2 inch
leg stretch, and a full 1 inch of backbone stretch provide the profile that chopper riders and builders strive for. DOM 1 1/8 inch
tubing is used through-out for strength and durability. Motor
mounts are CNC machined steel. The kit comes complete with
gas tank, oil tank and rear axle assembly.
WEST COAST CHOPPERs
718 West Anaheim Street
Long Beach, CA
(562) 983-6666 fax (562) 983-6556
This is the handlebar for the millennium. Wiring can be completely hidden for a clean, uncluttered handlebar look. Side plates are
made from hot-rolled ASTM A36 American steel. Ground on two
sides then machined inside and outside. Internal wire channels
hide the wiring. Tube components are 1” X .083 wall thickness
chrome-moly and knurled. Available with or without dimples.
Available also in black or chrome!
HILL PRODUCTS
(949) 515 9991
Totally OEM compatible is this economical chrome-plated tripletree assembly from Drag Specialties. Kits come complete with all
required components including neck bearings top and bottom,
dust shields, stem-nut & lock-washer, ready to “bolt-in” to your
existing frame. A stem nut cap is also included. Designed specifically for custom builder applications 1984099 FXST/C and 19841986 FXWG models, this trees can also be used with most 19491984 FL or FX models (not FLT or FXR), and after market frames.
They’re in the “FATBOOK” the big thick catalog from Drag
Specialties.
See your local Drag Specialties dealer.
J&J
HYPEREUTECTIC
BIG-TWIN PISTONS
J&J’s lightweight hypereutectic piston makes more power and runs
oh so quiet when compared to conventional forged pistons. It also
use less fuel and lasts longer. Forget about running loose fitting,
noisy pistons. J&J’s hypereutectic alloy keeps the heat in the combustion chamber reducing piston expansion significantly. J&J
hypereutectic pistons are installed tighter (half a thousandth) supporting the compression rings better for a more efficient seal. The
high ring placement reduces detonation and increases top compression ring temperature. J&J hypereutectic pistons are modern
technology applied to the V-Twin design to make more power for all
applications from street to strip.
J&J Pistons
5212 Camelback Road
Glendale, AZ 85301
phone/fax
(602) 931 4060
email wcoastchop@earthlink.net
www.westcoastchoppers.com wcoastchop@earthlink.net
4
5
Hard-Tail Hardparts continued
NEO PAN MOTOR FROM
PANZER
MOTORCYCLE WORKS
It looks like a real Panhead, and it is, sorta. A real Pan wouldn’t be able to
keep up with a Panzer Neo Pan motor because the Neo Pan motor uses
modern metallurgy, modern ignition components, and many other modern
upgrades. The cam is from Andrews, cases are STD or S&S, the distributor
is from Twin Power (billet aluminum) and the exhaust system is from
SuperTrapp with proprietary Panzer design implementations. A Cycle Electric
generator eliminates all the problems way-back-when Panhead owners are
all too familiar with. The ignition is modern, a “hall effect” pointless spark triggerer (pardon my pun). Lifters and guides are JIMS Machine, as are the pinion gear and pinion shaft. You get the idea, this is a Panhead power-plant that
will go the distance or even twice the distance that the old Panhead motor
would, and still be ready to roll. Get yours from....
PANZER MOTORCYCLE WORKS
P.O. Box 425
Canon City, CO 81215
(719) 269-7267
www.panzerusa.com panzer@ris.net
RIGID FRAME SOURCES
Atlas Precision
rigid frames
16901 Kamana
Apple Valley, CA 92307
(760) 242 9111
Chopper Guys
rigid frames
1633 Marine World
Parkway
Vallejo, CA 94589
(707) 557 2400
Denvers Choppers
1000 Stephanie Unit 12
Henderson, NV
(702) 450 0169
(complete turn-key bikes)
Gambler
Motorcycle
Company
128 Volunteer Drive
Hendersonville TN 37075
(615) 826 7777
Pacific Sunset
rigid frames
2659 Junipero Ave
Long Beach CA 90806
(800) 854 7218
(Edlund rigid frames)
Sundance
Components
girder forks
440 Shearer Blvd
Cocoa, FL 32922
(407) 636 3044
(frames, girder forks,
accessories)
The Shop
6541 Ventura Blvd
Ventura, CA 93003
6
Primo Belt Drives
S&M Cycles
12532 lambert Road
Whittier, CA 90606
(562) 907 2600
2834 Colorado Ave #51
Santa Monica, CA 90404
(310) 264-5957
WWW.s-and-m-cycles.com
(complete bikes)
Wheel Works
PAUGHCO INC (FRAMES)
Spyke
Motorcycle Creations
547 Apollo
Brea, CA 92621
(714) 990 1166
(paint/fabrication
restorations/motor work)
info@primobeltdrives.com
12787 Nutwood
Garden Grove, CA 92640
(714) 530 6681
call for catalog
12440 lambert Road
Whittier, CA 90606
(562) 693 2983
Samson
exhaust pipes
220 South Loara Street
Anaheim, CA 92802
(714) 518 2480
www.samsonusa.com
P.O. Box 3390
Carson City, NV 89702
(702) 246-5738
DAMONS
send your
RIGID FRAME SOURCE
listing to
HARDTAIL
MAGAZINE
2621 Green River Suite 105 Box 389
Corona, CA 91720 fax (909) 340 3303
Sifton Products
943 Bransten Road
San carlos, CA 94070
(415) 592-2203
Rivera
Engineering
12532 Lambert Road
Whittier, CA 90606
(562) 907-2600
JR’s Engine Service
1900 East 27th Street
Signal Hill, CA
(562) 427-8600
Le Pera
(seats)
8207 Lankershim Blvd
North Hollywood, CA
91605
(818) 767 5110
7
Crazy Art’s
HE’S BACK
HE’S BAD
CRAZY
CRAZY
ART’S
ART’S
KUSTOM
KUSTOM
KOLORS
KOLORS
Made in the USA
STRONGEST
THE MOST
RELIABLE..
motor & transmission cases available!!
!
W
NE
Delkron’s NEW “Bullet Design” gear cover with
improved breathing is manufactured from billet
6061-T6 aluminum for superior strength & durability! CNC machined for exact tolerances &
show polished for style, this cover will add class
to any Delkron “Cone-Motor” style cases (Evo or
Shovelhead). Pinion & cam bushings are
installed. The kit includes base gasket, mounting
screws, points cover, points cover screws, points
cover gasket, and a complete set of mountingscrew covers as pictured.
Gear Cover part number ......... GC-1
See your local DELKRON dealer or call DELKRON direct (916) 921- 9703
He’s forgotten more about
painting motorcycles than
most of today’s painters
will ever know! HarleyDavidson & Indian motorcycles only! Don’t even
mention Jap Bikes!
24 hours
8
(323) 725 0703
9
PRECIOUS
R
R
E
E
V
V
L
IL
K
K
S
SI
C
C
U
U
N
N
K
K
$$$
MONEY
TALKS
by Buck
staff photos
more than 2 years which must have created some anxiety even in a gamblers heart.
Fabrication was performed by S&M cycles,
the pace determined by Neil’s monetary
contributions. Paint and graphics were
also performed by S&M. The rare, or at
least hard-to-find in decent condition,
Knucklehead motor is an "FL" model (74
cubic inches) that was completely rebuilt
by Scott's Shop. The lower-end is an
exquisitely balanced S&S item. Both intake
and exhaust valves are Black Diamond,
held in place with Andrews valve springs.
An S&S Super E carburetor feeds the
motor on timed requests from an Andrew
"A" grind bumpstick. S&S push rods transmit cam signals from JIMS lifters to stock
rocker arms. Lifter blocks are HarleyDavidson originals. The Cam cover is an
S&M custom specialty item.
Sending the power back to the rear
Braking being as important a safety item as it is,
demanded the use of two
4-piston
Performance
Machine Calipers up front
(with floating rotors), with
a single unit out-back. You
can reach S&M Cycles at:
Neil AKA "The Gambler" is the owner of
this silver Knucklehead he calls money.
Silver is the color of money, at least most
of the coinage we have here in the USA is
silver in-color if not in content, or maybe he
named her money because he had to
spend a little to get the end result pictured
here. Fat tires at both ends makes for very
comfortable riding, at least when considering the fact that rigid frame motorcycles
don't take the bumps in the road too graciously. The rigid frame here being from the
"Swedish Guys" whoever they may be
(Pacific Sunset). Fabrication took a tad
(310) 264-5957
wheel is a Sputhe 5-speed in a 4-speed
case (Andrews gears). The primary drive
is a Primo Belt Drives "Brute Classic"
designed to give smooth, modern, beltdrive plus diaphragm spring operation to
older model Harley-Davidson motorcycles,
and is kick start only. A Swedish Guys rigid
frame with 38 degrees of neck rake gives
good freeway-speed handling, and is light
enough to make low speed steering easy
too. The frame is also wide enough at the
rear to accommodate a 180 wheel/tire
assembly. Up front a fat-for-the-front
140/18 wheel tire assembly leads the way.
Both front and rear wheels are RC Comp
units, with Avon tires mounted.
10
11
R
R
E
E
V
V C
L
IL
K
K
S
SI
C
U
U
N
N
K
K
FRAME ................. PACIFIC SUNSET
STYLE ................... WISHBONE RIGID
RAKE .................... 38 DEGREES
FRONT WHEEL..... RC-COMP 140/18
TECH
BIKES NAME...... “MONEY”
OWNER.............. Neil “The Gambler”
CITY ................... Venice, CA
YEAR ................. No Matter
MODEL .............. 1941 FL “Knuckle”
MOTOR TYPE ..... OHV V-Twin
DISPLACEMENT.. 74 cubes
IGNITION ........... MORRIS MAGNETO
CAM(S) ................ ANDREWS “A”
CARBURETION... S&S SUPER “E”
PISTONS ............. S&S
COMPRESSION .. 9.5:1
CON RODS ......... S&S
LIFTERS .............. JIMS MACHINE
HEADS ................ MASSAGED BY S&M
VALVES ............... BLACK DIAMOND
SPRINGS ............. ANDREWS
PUSH RODS ....... S&S
EXHAUST ............S&M CUSTOM
TRANSMISSION ..SPUTHE 4-INNA-5
REAR WHEEL ....... RC COMP 180/18
FRONT TIRE ........... AVON
REAR TIRE .............. AVON
FRONT BRAKES ...... PM 4 PISTON X2
REAR BRAKES ........ PM 4 PISTON X1
FRONT ROTOR(S).. PM FLOATERS
REAR ROTOR(S) .... PM FLOATER
MOTOR BUILDER .. S&M cycles
FORK ....................... TOLLE WIDE GLIDE
FRONT FENDER...... S&M CYCLES
rear fender ........ same as above
SEAT......................... Bill Wal Leathers
TAILIGHT ................ S&M CYCLES
ANYTHING EXTRA SPECIAL?
HARDTAIL
M
A
G
A
Z
I
N
E
YOUR AD
HERE!!
13
:
O
T
W
O
H
STAFF REPORT
Way back in 1973 before electric-start
was genuinely trustworthy and everybody relied on the kicker to start their
motorcycles, Primo Belt Drives was
just getting started in the belt drive
business. Without boring you with the
details, Mel Magnet bought out Primo
George, and as they say “the rest is
history.” Primo Belt Drives has come a
long way from the relatively simple belt
drive systems of the past which consisted of two pulleys and a belt utilizing
OEM clutch components. Today’s modern belt drives must pass rigid highmileage testing before being offered to
the public. Today’s Primo Belt Drive kits
contain years of experience and all the
“Quality & Performance” modern technology, and a dedicated crew can offer.
Watch as we install a Primo Brute IV
primary belt drive system. The Brute IV
intended for Softails & Dyna-Glides is
the same Brute IV installed on many
rigid frame custom & high-performance
motorcycles. We didn’t have a rigid
frame motorcycle available for the
installation so we cropped the photos
to hide the rear suspension. We don’t
like it anymore than you do, next installation we’ll use a rigid. Primo Belt
Drives can be reached at:
Install Primo Belt Drives
BRUTE IV
electric start
OPEN 3” Belt Drive
Step 1: All OEM primary drive-train components are
removed. Everything is cleaned thoroughly and inspected
for hidden damage prior to step 2. Check the threads in all
the mounting holes, and clean as needed.
STEP 3: Install the bearing support. Carefully align the boltholes and install the bearing support over the starter extender. Only hand tighten the bolts at this time. Attach the 1990
or later starter motor to the rear of the bearing support.
PP-400
Step 2: Install the starter extender into the starter
motor as shown. This component must be installed
prior to installation of the bearing support.
STEPS 3B & 3A: Primo Belt Drives PP-502 Motor
Plate assembly (rear section) for Dyna Glide is notched for
swing arm pivot-boss clearance. Approximately .100” must
be removed from the end of the nut & swing arm pivot bolt
assembly to allow clearance for the Brute IV ring-gear
before installing the clutch basket. Carefully remove only
enough material from the end of the nut & bolt to allow
approximately .100” clearance between the ring gear & the
nut-bolt assembly.
12532 Lambert Road
Whittier, CA 90606
(562) 907-2600
fax (562) 907-2606
email mel@primobeltdrives.com
The Brute IV belt drive system should be ordered complete as shown. The two aluminum pieces at the bottom are for Shovelhead 4-speed applications only. The billet
transmission arm can be ordered with splines rather than the square hole. A special
“splined” clutch release shaft is also available from Primo. The full coverage starter support housing keeps rocks and other debris from coming in contact with the ring gear.
The 2-piece motorplate is every bit as solid as a single piece unit with the added benefit
of easy fitment where & when motor & transmission alignment is not perfect.
14
STEP 4:
Install the Motor Plate (front section PP-303, PP-403, PP503, or PP-603), start the four front section bolts, but only
hand tighten at this time!
STEP 5: Install the 4 center bolts that attach the front section of the
Motor Plate Assembly to the rear section. Tighten the motor plate
bolts, the bearing support bolts and the center bolts at this time,
while ensuring that the plates are properly seated and aligned. If you
have purchased a PP-400 (show chromed alternator rotor cover)
install it now!
15
STEP 6:
Apply high-quality PRIMO BELT DRIVES bearing grease to the
transmission main-shaft splines to act as a corrosion inhibitor.
The grease also protects the splines by absorbing shock-loads &
preventing rust.
STEP 11: Remove the front pulley. Wrap the belt around
slide the front pulley into the belt. Slide the front pulley onto
and tighten the nut (Use Rivera “Blue” threadlock. With a
there should be enough slack in the belt to allow the front
slide into place.
the rear pulley,
the motor shaft
cold drive-train
pulley to easily
STEP 7: Install the starter coupler mechanism (coupler,
extender, spring, pinion gear, thrust washer, lock washer, and
bolt). Make sure the lock washer is correctly oriented, and
tighten the bolt. Bend the locking-tab over to keep the bolt
from vibrating loose.
STEPS 12 & 13: With both pulleys and the
belt installed the clutch plates can now be
installed. Install the clutch plates in exactly the same order as they were shipped. A
steel plate first, then a fiber, alternating
until all the plates are installed. Last plate
in is a steel. When in doubt, call Primo Belt
Drives, and consult a technician.
STEP 8: Install the rear pulley (clutch basket) and hand tighten
clutch hub nut (make sure it is snug). If you’re installing the Brute IV
on a Dyna Glide, check for clearance between the rear of the starter
ring gear and the swing arm pivot nut/bolt assembly. If needed
remove additional material from the bolt and nut.
STEP 14: Apply high-quality anti-seize compound to the the threads of
the Pro-Clutch studs to prevent the shouldered nuts from sticking to the
clutch hub studs when disassembling the clutch.
STEP 9: Install the front pulley & nut (hand tighten to snug). Check alignment of the pulleys by placing a straight edge flush with the inside lip of the
clutch basket as shown. If needed, spacers can be used behind the front
pulley to correct minor mis-alignment. The straight edge should line-up flush
with both the inside of the front pulley lip and the inside of the clutch basket
lip. Space the front pulley as needed for alignment. Available is a laser
etched, number front pulley (as shown).
STEP 10: After checking and/or correcting pulley alignment, permanently
install the rear pulley & hub assembly using Rivera “Blue” threadlock or
equivalent. Torque the main shaft (clutch hub) nut to factory specifications
(90-100 foot pounds of torque).
16
STEP 15: Install the pressure plate diaphragm spring, spring
retainer (beveled side in) and shouldered nuts. Make sure the
lock-tabs are in place!
17
STEP 16: Tighten the shouldered nuts
equally until they bottom, and then tighten to
30 INCH POUNDS (not foot pounds) of
torque. Install the clutch adjustment screw &
adjust the clutch following factory procedures as found in the Harley-Davidson service manual. Bend the lock tabs over to prevent the nuts from coming loose.
STEP 17: Install the starter support housing (over the starter
extender mechanism) as pictured. Carefully locate the housing
to align the bolts. Check to make sure the starter can turn freely
as you tighten the bolts.
HARDTAIL
Magazine
Inside you’ll find only the best in Chopper style
motorcycles with a Classic of the Month, and a “Rat
Bike” feature to make things interesting! Are you a
rigid frame motorcycle rider? If so, you gotta read
HARDTAIL Magazine. We promise not to show you
any Softails, FXRs, or Dyna Glides with tons of junk
bolted on, just hard-core rigid frame machines with
CLASS! If you missed the first 3 issues you can still
get’em as back issues, but they’re really going fast
so don’t delay! Subscribe today, $19.95 gets you 12
issues of the all new HARDTAIL Magazine! Can you
say CHOPPER??
THE “RIGID FRAME” MOTORCYCLE MAGAZINE
OPTIONAL ACCESSORIES FOR BRUTE IV
This is what your installation
should look like. Be sure and
install either the belt guard
that came with the kit, or
Part number PP-411 (Softail
show chromed guard) PP611 (FXR show chrome
guard).
A
W
E
S
O
M
E
CO
OM
MP
PU
UT
TE
ER
R
C
s
k
c
Bu
SCREEN SAVERS
Buck’s Antique Motorcycle Screen Saver ...50+ images
order number BAM-1
.......................................$24.95
Buck’s Crocker & Indian Screen Saver .......50+ images
order number BCI-1
.......................................$24.95
Buck’s Old Cop Bike Screen Saver .............50+ images
order number BOC-1
........................................$24.95
Buck’s Tank Art Screen Saver ......................50+ images
order number BTA-1
.......................................$24.95
The Perfect CHRISTMAS gift! order number BCS-1
18
.......................................$24.95
PMB 389
2621 Green River Suite 105 Corona, CA 92882-7454
909 340 3111 fax 909 340 3303
Dealer Pricing
on request
Buck’s Chopper Screen Saver .....................50+ images
19
from
V-TWIN
CITY
?
N
W
O
D
E
E
R
H
T
.
.
P
U
ONE
2020
TECH
BIKES NAME...........Hard-on the back
OWNER..................... Bones Faddock
CITY ..........................Lake Elsinore
YEAR ........................ 99
MODEL ...................... FL
MOTOR TYPE ........... Shovelhead
DISPLACEMENT........ 80 Cubic inches
IGNITION .................. DYNA-S
CAM(S) ..................... NA
CARBURETION.........SUPER “E”
PISTONS ...................S&S
COMPRESSION ........ 9:1
CON RODS ...............S&S
LIFTERS ....................HYDRAULIC
HEADWORK............ALAN TUCK AT
V-TWIN CITY
VALVES/SPRINGS ....S&S
PUSH RODS .............ANDREWS
TRANSMISSION .......1980 4-SPEED
PRIMARY DRIVE ..... PRIMO BRUTE IV
3” WIDE ELECTRIC START BELT DRIVE
FRAME ......................JAMMER
EXHAUST ..................RUN ROADER
FRONT WHEEL......... 21” AVON
REAR WHEEL ...........160/16 AVON
FRONT BRAKES ......HD
REAR BRAKES ........GMA
MOTOR BUILDER .....Alan Tuck
FORK .........................HD WIDE GLIDE
FENDER(S) ...............2
SEAT........................... Spring bates
TAILIGHT ...................SUMTIN FUNKY
V-TWIN CITY 802 TOWNE CENTER DR. POMONA, CA 91767
TEL 909 399 3595 FAX 909 399 3593
21
advertising space is available in
A 12 Issue subscription to Hardtail Magazine is available for $19.95.At this time we will only accept black & white
advertising and will NOT accept any ad that does not contain material pertaining to rigid frame motorcycles (rear shocks,
swingarms & and other suspension components.) Hardtail Magazine is published 6 times a year unless conditions
dictate otherwise. Your ad will be placed as prominently as possible on right-hand pages as available. At this time no color
pages are available for color ads. For all further information or to subscribe to Hardtail Magazine please contact:
HARDTAIL MAGAZINE
PMB 389
2621 Green River Suite 105
Corona, CA 92882-7454
(909) 340 3111 fax (909) 340-3303
22
23
GROOVY
WHEELS?
by Buck Lovell
The crew at JIMS Machine has been busy.
You can count on the JIMS team to innovate or improve upon existing products or
components in such a fashion as to make
the old version(s) obsolete. Take these new
flywheels. The flywheel assemblies ready
to install have been trued and then balanced at 60 percent (with JE 9.25:1 compression pistons) to make life easier for
serious motor builders. Stroke is 4 5/8 inches with a 7.440 inch rod length. The flywheel assembly is shipped with standard
length sprocket shaft (drive side) and pinion shaft (cam side) so as to “bolt-in” to
standard 1984 to present motor cases with
standard pinion races (24599-58B, 2459958A etc.). They can also be used with pinion bearings (JIMS 24628-87). For 1990to-present use JIMS pinion gear 24043-78,
oil pump drive gear 26349-84 with JIMS
keys 2480 & nut 24023-54. JIMS makes it
simple to arrive at the configuration you
want. Flywheel assemblies are available
with standard bore pistons (again 9.25:1
compression ratio) part number 1900-A,
plus .005 pistons part number 1900A5, or
plus .010 pistons part number 1900A10.
Note also that these flywheel can be used
in Shovelhead applications 1970-1984.
Pinon shaft is standard with end-oiler. The
sprocket shaft is JIMS “big-taper” with key.
Manufactured from the finest American
cold drawn steel the flywheels have been
re-engineered & designed with performance in mind. One new feature, and a real
biggy for speed-freaks is the machined-in
“windage groove” which works with the
angled counter weights
to deflect
crankcase oil into the scavenge port much
more effectively than any conventional flywheel. These are the most oil-dynamic flywheels available today. Cooler operation
and less drag means more horsepower for
the rear wheel. In addition a deflection
windage device (when used with JIMS
rods) helps lubricate and cool the bottom
of both pistons. Three grooves around both
crank-pin thrust faces bolsters rod
strength, and increases lubrication in this
critical area. The conventional location in
the rods themselves has been eliminated,
which reduces the potential for cracks or
fractures under high horsepower stresses.
Critical machine tolerances are held to a
phenomenal .0003” (A JIMS specialty)
24
making these flywheels easy to assemble
balance, and true. How many reasons do
you need to switch to JIMS flywheels?
Here are some other reason we are using
JIMS components in our project flywheels.
The connecting rods are finest pieces of
workmanship we’ve seen in a long time.
The JIMS R&D team researched & identified the weaknesses in existing connecting
rods, then designed their rods to avoid
these traditional pitfalls. JIMS rod are manufactured exclusively from aerospace certified 4340 moly steel. The rods are then
CNC machined on the latest equipment.
Each rod is then heat treated, magnafluxed, and shot peened. It is then reinspected and given a hardness test. The
rod then goes back to the CNC mill to have
the rod race bore machined relative to the
wrist-pin bore to within .0003” of oneanother. Bore finish is 32. The wrist pin
bushing oiling holes is optimized for
improve lubrication in this critical area. The
“H” beam design was chosen for its exceptional strength and flex resistance. “H”
beam rods are more time consuming and
difficult to machine correctly but the JIMS
R&D team felt the extra effort was justified
by the end result, a rod that stands above
all others. Each rod-set has rod-races &
wrist pin bushings installed, and fitted
to factory specifications. Several
lengths are available including;
7.440 inches, 7.690 inches”, and
8.250 inches. Part number 4000.
Top drawer JE forged pistons are
supplied with all JIMS flywheel
assemblies (complete). We are very
familiar with these pistons, they are in
place in the editors motorcycle (9.25:1
compression ratio) which had more than
90,000 hot-rod miles on the clock. Valve
reliefs are machined into the flat top to
accommodate most oversize valves and or
cam lifts. A Hastings moly-filled top compression ring, with a Hastings compression reversed “torsion-type” second ring
preclude blow-by, with a 3 piece oil-ring
wiping and oiling the cylinders. Part
number 1904A. Don’t confuse JIMS
high-performance motor components
with the others. JIMS products have traditionally exceeded the performance and
durability requirements of today's high performance motorcycles by a wide margin.
Just ask any JIMS customer. Quality is
unqestioned, Performance is built-in. It’s a
long-time JIMS tradition!!
Note the position of the “windage groove” in the left flywheel.
This groove coupled with the angled counter weight efficiently diverts crankcase oil into the scavenge port virtually eliminating windage due to excess oil in the crankcase. “Wet
sumping” is eliminated with JIMS flywheels.
25
The bik
r
o
h
S
s
i
e
m
a
n
l
a
e
r
es
.
.
.
.
s
’
t
i
k
n
i
h
t
e
w
t
ty, bu
Pure & Simple
by buck Lovell
photos by Buck Lovell
If you're a genuine hardcore motorcycle
rider I guess one of the best places to
live would be Las Vegas, Nevada. Wide
open stretches of highway abound in
this arid Southwestern state, and the
roads are typically well maintained. A
smooth, unpotted road surface is much
desirable when riding a rigid frame
motorcycle, considering the alternatives.
Craig Michael is a long time motorcycle rider, and long time bike builder since
the late sixties. These days Craig is a
general contractor in Las vega, Nevada.
With more than ten motorcycle projects
under his belt (four of which were
Denver's Choppers machines) Craig
Switch boxes are show chrome.
knows exactly what he wants in a twowheeler. No Softail wanted or needed
here. The rigid frame bike featured on
these pages is one of the cleanest, neatest Choppers type machines we've
seen in a long time. Traditional stripped
silhouette with no extraneous baggage,
Craig named her "Shorty", but we decided to call her "Pure & Simple."
Craig commissioned the recently reopened
Denver's
Choppers
of
Henderson Nevada (near Las Vegas)to
build this bike per his specifications and
riding style. The original Denver's Shop
was located in San Bernardino,
California. Denver was killed
tragically is a boating accident
about ten years ago. Mondo, one
of Denver's closest friends, and
the man who performed the
molding chores at the original
shop, has reopened
Denver's to satisfy the
tremendous contemporary demand for high
quality, high performance "chopper style"
Harley-Davidson motorcycles.
Craig met Denver
while living in the
Huntington
Beach,
California area in the
early 1970's. After seeing some
of Denver's outstanding customs, he had to have one for
himself. After taking delivery of
his first ground pounding, fire
breathing, rigid framed "Denver's
Chopper" Craig was hooked. The radical
front-end, and far-out styling was, and
still is an ego trip. We all know what it's
like to take an everyday ride, only to
have people comment on how awesome
our motorcycle is. That's just part of
chopper riding.
When Craig heard that Denver's was
re-opened and operating in Henderson,
Nevada he immediately took the time to
make a visit. After meeting Mondo, and
spending hours reminiscing, Craig was
hell-bent to get another project bike
started. Motorcycle riding is a habit that's
difficult to kick.
Mondo had a Paughco rigid frame with
Foot controls look as good as they
oughta on a bike like this
a 6" over Paughco Springer laying
around. Craig decided this would be the
perfect combination for a bar-hopper,
bad-ass-chopper in the seventies tradition. The rear fender is custom made,
(not factory custom, but one-of-a-kind)
as is the removable sissy-bar, brackets
CCI Side-mount license plate is still
legal we hope!
A properly designed and constructed rigid frame motorcycle can be every bit as
comfortable as a conventional motorcycle. Craig’s feet are flat on the ground, knees
bent when stopped. This motorcycle was custom built (not factory custom) to suit
his riding style, and his motorcycle riding history.
and seat. If it's made at a factory, it ain't
custom, no matter what the Harley adhype says. The Paughco frame was subjected to hours of rework and modifications to accept a 180 rear wheel and tire
assembly, and 5-speed Sputhe transmission. A color coating was next on the
shopping list. "Feet" or Mr. Feet to some,
at JD Custom Paint applied the deli-
27
cate, dark purple paint scheme seen on
pages 19, 20, and 21. APS performed
the chroming chores. Mondo and Craig
gathered together all the needed
remaining components to get this
machine ready for the road. After many
months of riding and too many kicks to
count, and electric start was added. Old
memories can stay that way, electric
start is too convenient and dependable
to ignore. A Primo Brute IV primary belt
drive system was selected to move
ponies from the source to the transmission. The original Denvers Choppers
used Primo Belt Drives on many custom
bikes way back when, and Primo is still
number one for virtually any application.
Craig and Mondo are now in the
process of designing a long fork bike for
Craig. A mean, lean chopper for long distance freeway riding.
TECH
BIKES NAME............. “Shorty”
OWNER..................... Craig michael
CITY .......................... henderson, nevada
YEAR ........................ 1998
MODEL ...................... chopper
MOTOR TYPE ........... evo big-twin (now a classic)
DISPLACEMENT........ 80 cubic inches
IGNITION .................. CRANE HI-4
CAM(S) ..................... SCREAMIN EAGLE
CARBURETION......... S&S SUPER “E”
PISTONS ................... HD
COMPRESSION ....... 9:1
CON RODS ............... HD
LIFTERS .................... JIMS HYDRAULIC
HEADS ...................... HD
VALVES/SPRINGS .... HD
PUSH RODS ............. TAPER-LITE
TRANSMISSION ....... 1999 5-SPEED
TECH
FRAME ...................... PAUGHCO (35 DEGREE RAKE)
EXHAUST .................. SAMSON STREET SWEEPERS
FRONT WHEEL......... 21
REAR WHEEL ........... 16
FRONT BRAKES ...... DUAL PM ROTORS/CALIPERS
REAR BRAKES ........ SINGLE PM ROTOR / CALIPER
MOTOR BUILDER .... denvers
FORK ......................... PAUGHCO SPRINGER (6” OVER)
FENDER(S) ............... DENVERS CUSTOM REAR
SEAT........................... Denvers
TAILIGHT ...................CCI
28
SPECIAL FEATURES
BRAIDED OIL LINES, CUSTOM REAR FENDER, REMOVABLE SISSY
BAR, 85 HORSEPOWER, 5-SPEED SPUTHE KICK START IN FOUR
SPEED CASE, APS CHROME PLATING, PRIMO PRIMARY BELT DRIVE,
PRO CLUTCH, AND MUCH MORE.
29
PRIMO BELT DRIVE transmits the
horsepower to the transmission.
Primo has a belt drive for virtually any
Big-Twin application.
Pure & Simple
30
Big-Twin with an S&S is freeway
and back-road qualified. Chrome
exhaust pipes may turn blue with all
the ridin this bike will see.
Nothing says Harley-Davidson
like a Springer. Big-headlight
puts out plenty of light for night
time Nevada riding.
Clean, integrated styling is contrary to most of todays “bolt
everything on including the
kitchen sink” thinking. Daily riding means daily cleaning.
31
“Easy to install, and easy to determine on, off and
reserve with looking down, I will be using Peak Flow petcocks on on my motorcycles from now on.. California
uses MTBE in the gas and I’ve had to replace at least
two petcocks in less than a year before the Peak Flow
was available!”
......Buck Lovell, Editor, HARDTAIL MAGAZINE
“PEAK FLOW”
PETCOCKS & GAS FILTERS
Golan Products has a winner in our opinion. HARDTAIL Magazine tested both the petcock and the filters, and they are going to give
the competition a run for their money. The name tells the story, “PEAK FLOW” petcocks (gas valves) and fuel filters are superior to
most and have a 5 YEAR WARRANTY. Flow is more than 70 oz. of gas per minute in either on or “closed-loop” reserve position
(with no air bubbles in reserve. Space-age wear-resistant Delrin piston provides leak free, worry free “off” position. Delrin is also
impervious to common gasoline additives such as MTBE & Ethanol this means the Peak Flow petcock is safer for us in states using
these additives in their gas.. Extra wide spacing of on-off-reserve positions eliminates dangerous fumbling for reserve when in traffic for smooth positive transition to reserve. This petcock is also easily & economically rebuildable, and industry first. The Peak Flow
is manufactured from chrome plated 360 brass, Delrin, & stainless steel components. Matching filters are available: Dealer inquiries
are welcomed. See your local Rivera Engineering, Custom Chrome, Nempco, Arlen Ness, or Mid USA dealer. MADE IN THE
USA!
GOLAN PRODUCTS 4404 Elenda Street Culver City, CA. 90230
phone 310-204-5554 fax 310 837-5361
CHOPPER ART
SEND US
your rigid frame chopper
art as hand drawn, computer
d r aw n ,
pencil
d r aw n , m e lt e d c r ayo n ,
d u s t y pa s t e l , s p l at t e r e d
i n k , N ava j o s a n d , l a s e r b e a m , s k e tc h e d , e tc h e d ,
c h i c k e n s c r atc h e d , c h a r coal, or any damn media
you are proficient in to :
Chopper Art
PMB 389
2621 Green River Suite 105
Corona, CA 92882-7454
35
R
E
W
R
E
O
P
W
O
FL
the
FLOWER POWER
A Bad Bar Hopper sorta
by Buck Lovell
If you've been riding American motorcycles
long enough, say 30 years or more, you're
not the"New Breed of Rider" as some are
labeled in another consumer motorcycle
magazine. You're the "Old Breed," and
years of experience dictates many of your
riding behaviors and tastes. Billet aluminum is not the answer to everything, it's
just expensive. New breed riders buy it by
the bucket-load. We can't bring back the
good-old-days, but we can enjoy the current renaissance of rigid frame chopper
style motorcycles while it lasts, and we
may even participate in the runs and parties. Old breed riders LOVE TO PARTY.
PRISMIK CHOPPER
Until the massive invasion of foreign
motorcycles with racing posture seating
and more horsepower than common
sense, "handling" usually meant how well
your motor steered under full-throttle quarter mile blasts. Choppers were meant for
freeway cruising or "puttin" as we know it,
and we enjoyed puttin anywhere, anytime.
This motorcycle is probably already
enroute to it's new home in Japan, where
puttin, and all thing American from the
1970's is all the rage. Choppers, bar-hoppers, and dressing like an American biker
from the 1970's is more popular than rice,
well maybe not, but it's the happening
thing. Chica, of Chica's Custom Cycles in
Huntington Beach, California builds chopper, bar-hopper motorcycles for the
Japanese market heavy with 1970's
American styling. The Denver's Choppers
TECH
--------------------------------------------------BIKES NAME............. Flower Power
OWNER..................... CHICAS CUSTOM CYCLE
CITY .......................... HUNTINGTON BEACH, CA
YEAR ........................ 1948
MODEL ..................... Bar hopper
MOTOR TYPE .......... panhead
DISPLACEMENT........ 74 cubes
IGNITION ................. POINTS
CAM(S) ..................... HD
CARBURETION......... SU FROM RIVERA
PISTONS ................... HD
COMPRESSION ....... 8:1
CON RODS ............... HD
LIFTERS .................... HD
HEADS ...................... HD
VALVES .................... HD
SPRINGS ................... HD
PUSH RODS ............. SIFTON
EXHAUST ................. CHICA CUSTOM CYCLES
TRANSMISSION ...... STOCK 4-SPEED
TRANS SPROCKET .. 24
GEARS ...................... HD
MOTOR SPROCKET . 23
PRIMARY DRIVE .... PRIMO 3” OPEN BELT
FRAME ..................... DENVERS
RAKE ........................ 40 DEGREES
MATERIAL ............... N/A
FRONT WHEEL......... 19”
REAR WHEEL ........... 16”
FRONT BRAKES ...... PM 2-PISTON
REAR BRAKES ......... PM 4-PISTON
MOTOR BUILDER ... Chica Custom Cycles
OIL BAG ................... CHICA CUSTOM CYCLES
FORK ........................ DENVERS
FRONT FENDER ....... HA HA HA
Rear Fender ......... Chica Custom Cycles
gas tank ................ Prismik?
SEAT........................... Chica Custom Cycles
TAILLIGHT ................. CCI DIAMOND
ANYTHING EXTRA SPECIAL?
Stainless steel oil lines, 1970’s styling, Z-Bars with
Pat kennedy grips, side-mount license plate,
20" over Springer (Denvers was making
super-long springer forks in the 1970's)
seen here is perfect for the rigid frame barhopper (which will probably never be seen
at a bar) as is the long Z-bars and layedback (into to the old-ladies groin) seating.
Relax, go for a ride it says to all. The motor
is a genuine 1948 Harley-Davidson FL
(Panhead to Old Breeds) and displaces 74
cubic inches. It has points for ignition, and
every thing else in the big V-twin is stock. It
makes enough ponies to push the lightweight Denver's Choppers frame down the
freeway at legal-plus speeds.
The transmission is a four speed Harley-
Davidson unit that is handshifted, using a wellchromed OEM rocker footpedal unit to engage and
disengage the clutch. The
frame is from the reborn
Denvers Chopper shop in
Henderson, Nevada. Front
wheel/tire assembly consists
of a 19" steel rim laced to a single disc hub,
the rotor of which is pinched by a dual piston Performance Machine caliper. The rear
wheel assembly is a 16" rim laced to a dual
flange hub, with a single four piston caliper
pinching the 11.5 inch rotor. Chica's
Custom Cycle can be reached at (714)
842-4587.
The ha nd wr i ti ng i s o n the wa l l , c ho p p e r s a r e b a c k , s o i s p u r p l e (i t wa s ne ve r r e a l l y g o ne ) a nd s o a r e b e l l -b o tto m s , a nd hi p p y b e a d s ! Fr e e l o ve . . . . . ??
FL OWER POWER
Chica Custom Cycles, Huntington Beach, CA
HARDTAIL
The rigid frame motorcycle Magazine
PRESENTS
A RIGID FRAME
MOTORCYCLE
SHOW
ALL BIKES WELCOME,
ONLY RIGIDS will be judged!
BAR-B-QUE!
BEER!
MUSIC!
1PM-to-5PM
TROPHY FOR
BEST RIDDEN
RIGID FRAME
Motorcycle
A SMOOTH
RIDE FROM
ANYWHERE
IN THE
L.A. BASIN
BBQ GIFT
CERTIFICATES
& RAFFLE PRIZES
RIGID FRAME RIDE-IN
at BACKWOODS BBQ
4300 Green River at the 91 Freeway
Corona, CA (909) 371 7227
Every 3rd Sunday of the Month
Vendor display space is available first come first served basis ..... $20 FOR A 20’ WIDE x 10’ DEEP SPACE
ENERGY ONE
high performance Clutch components
Energy One is the new kid on the block.
The new CLUTCH COMPONENT KID
that is! Energy One has more than 20
years of manufacturing experience in the
automotive, and motorcycle clutch component arena. Clutch plates, spring and
related components are produced in
house from American made materials for
the highest quality. All clutch plates are
manufactured from either 6061-T (aluminum) or high-tempered steel, and
CLUTCH DISC SET
FOR BIG-TWIN
1941-84
lined with Energy One's own proprietary
Kevlar friction material. Energy One
clutch components meet or exceed all
the competition's specifications making
Energy One clutch components not only
the best choice for performance applications, but the most cost effective as well.
Energy One's new and unique groove
patterns allow maximum oil circulation
with wet clutch applications for smooth
positive clutch engagement, and race
winning control. Heat dissipation is optimized. All Big-Twin clutch plate kits are
packaged & shipped with the required
fibers and steels with the required pack
height specification for quick, easy
installation. The exceptional quality and
fit of these new components will be
appreciated by professional racers as
well as high performance chopper riders.
(562) 698 7809
Ed.
STEEL PLATES
FOR BIG-TWIN
1941-84
6-STEEL PLATES
CLUTCH DISC SET
SPORTSTER
CLUTCH DISC SET
SPORTSTER
1984-90
7 KEVLAR
FRICTION PLATES
ALUMINUM CORE
6061 -T6
THRU 1970
7 KEVLAR
FRICTION PLATES
ALUMINUM CORE
6061 -T6
SP-7
SP-9
FRICTION DISCS
SPORTSTER
1971-84
8 KEVLAR
FRICTION PLATES
STEEL CORES
BTS-5
SP-8
5 FRICTION
5-STEELS
BT-5
EXTRA PLATE KIT
FOR BIG-TWIN
1941-84
6 FRICTION
6-STEELS
BTX-5
CLUTCH DISC SET
FOR BIG-TWIN
1990-97
CLUTCH DISC SET
FOR BIG-TWIN
1990-97
9 FRICTION
7 STEELS
8 FRICTION
6 STEELS
BTX-11
also
BT-11
91 Later Sportster
CLUTCH DISC SET
FOR BIG-TWIN
1998-up
9 FRICTION
8 STEELS
BTX-14
44
45
N
E
I
T
S
N
E
K
N
A
FR
FRANKENSTEIN
By Buck Lovell
Photos by Buck Lovell
Frankenstein was a monster, or more correctly he was named after the doctor
(Frankenstein) who created him. It matters
not, the name Frankenstein has become
synonymous with monsters. Dan probably
46
named this old-school, fabricated-in-thegarage motorcycle Frankenstein because it
has quite a few parts and components that
were never intended to be assembled
together. The Frankenstein monster was
truly a custom creation, and so is this
Frankenstein. From now on Frankenstein
will be "Frank" because my hand is getting
tired of typing, O.K.?
Dan Mergell is a hardcore motorcycle
rider by any standard. He also builds the
motorcycles he rides, and builds them the
old fashioned way, with his own hands, and
tools. Frank is truly a custom motorcycle in
that it represents the individual taste, skills,
and preferences of the owner, and he
doesn't really care if YOU like it. He only
cares that he likes it. Frank is a 1973 &
1957 Harley-Davidson "cone-motor"
Shovelhead. Rebuild time was right at 1 full
year after the wreck (that's what the tech
sheet said). All fabrication and assembly
work was performed personally by Dan
Mergell. All the shiny stuff was plated by
Buena Park Chrome in Buena Park,
California, where else? Paint is by Dan with
striping by Ken's Mobile Pin Stripe (I didn't
know there was enough demand to keep a
mobile pinstriper busy!).
The Big-Twin power-plant is circa 1973
(FX) and displaces 84 cubic inches.
Rebuild was performed by you guessed it,
the owner. The lower-end is Truett &
Osborn flywheels inserted into Delkron
cases, and mated to a set of S&S connecting rods. The balancing was performed
by Fast Eddie. Forged pistons are from
S&S and tout a 9:1 compression ratio, for
mucho pop. An Andrews "C: grind cam
works with Sifton "Shortie" lifters, Crane
roller rockers, and Sifton push rods (see
why it's called Frankenstein?) to open the
valves on a tighter schedule than any airline. The ignition system is HarleyDavidson deriving spark from Dyna dualtower coils. Extra special flow-magic headwork was performed on S&S cylinder
heads by Dave Mackie, the best-in-thewest when it comes to custom headwork.
An S&S Super E carburetor feeds this well
intentioned Big-Twin for fast freeway flying.
All the ponies produced by this radical
Shovelhead power-plant are transferred to
the transmission by a 2" Primo Belt drive
system. Motor pulley is 47, clutch basket
pulley is 76, for a 1.61-to-1 primary drive
ratio, perfect for hard leaves from green
lights. Chain drive to the rear wheel is via a
24 tooth transmission sprocket (sprockets
for chains, pulleys for belts) and a 48 tooth
rear wheel sprocket. A now famous Rivera
"Pro-Clutch" puts the power in the box. The
transmission case is a Cal Products item.
All the previously mentioned body parts
are positioned for go in a 1957 HarleyDavidson "straight-leg" rigid frame that has
been conveniently stretch 2" while retaining the stock rake specification. Mounted
47
on top is a 3.3 gallon Sportster gas tank. It
has also been subjected to "stroker reinforcement" to keep it together under the
stresses that a stroker can put out. The
seat is a real springer, so Dan
Hemorrhoids can live through the summer.
We don't know if Dan has hemorrhoids, it
just sounds funny (it's late, I'm tired). The
fork is a very special item that was scalped
from a 1941 Indian Scout. It has been modified to look like a Crocker Big-Twin fork. If
you don't know what I'm talking about,
you're a RUB. Where the hell is the brake?
There isn't any. If god intended choppers to
have front brakes, yadda, yadda, yadda.
Jerry Seinfeld would be proud. The wheel
assembly is a 19" rim and Metzler tire
laced with 40 spokes (American) to a steel
spool, origin undisclosed. Out back a dual
flange Harley-Davidson hub is laced to a
16 rim with a 150-80 Dunlop rubber donut
mounted. A Jaybrake (from Rivera
Engineering) 4-piston caliper pinches an
11.5 inch rotor when it's time to stop rolling.
Stainless steel drag bars on top of 3 inch
dog-bones allow fast accurate steering for
negotiating LA street and freeways. Fast
48
FRANKENSTIEN
steering makes up some for the lack of
front brake, but luck is also a factor as is
rider skill & experience. If you've been riding as long a s Dan, and you're still alive,
you're lucky, skillful, and experienced.
That's my story and I'm stickin to it. The
headlight is a spring type 5 ¾" diameter
thing. Tail light is Cateye What else? Do ya
like the bike? WE DID, and still do. You'll
see more from Dan right here on these
pages. He has a Springer equipped
Shovelhead we can't wait to show ya.
46
FRANKENSTIEN
RIGID Frames
DAYTEC
CHOPPER STYLE
rigid frame seen on the left is
103+200 capable with 6” stretch . And
yes, all your motor transmission stuff
will bolt-in without grinding & other
modifications..
DAYTEC showcase chopper is lean and mean, which is exactly what being a chopper is all about!
Daytec’s reputation for high quality
motorcycle frames for Harley-Davidson
motorcycles is a given. Clean, high quality finish with all the holes in the right
places means your motor and transmission will bolt-up with no modifications.
High quality D.O.M. (drawn over mandrel) steel tubing is used for a lightweight
but exceptionally strong finished product. All frames are stress relieved for
long term durability. Any customer specified stretch or rake can be ordered for
radical custom projects. High horsepower applications can utilize either the
103+180 chassis, or the 103+200 chassis which has a 1/2” thick billet steel
transmission plate welded into the
frame. This steel plate is designed to
absorb all the punishment a big-motor
can dish out with failing. For everyday
street applications Daytec’s “Street
Scene” chassis kit will accept either a
180 wheel/tire assembly with full size
rear drive-belt, or a 200 wheel/tire
assembly with chain-drive out back.
Daytec also carries a full line of rigid
frame accessories such as the “shorty”
chain guard etc. Daytec can do the frame
you want for street or strip, give’m a call.
17469 Lemon Street
Hesperia, CA 92345
(760) 244-1591 fax (760) 244 6373
Left side of the DAYTEC show case bike exhibits primo belt drive and shorty belt guard!
52
53
103+200
103+180
STREET SCENE
103+200
5” Top Tube Stretch
8: Leg Stretch
Shorty Belt Guard
54
55
RIGID RIDERS
Dear Hardtail:
I have always liked motorcycles especially
choppers (the more radical the better). I am
an airline pilot by profession and the bikes
are my relaxation and recreation from the
job stress. I ride this bike regularly, it rides
great. Enclosed are a few snapshots. I am
very interested in having my bike in your
magazine. I am planning another chopper
that I hope will be an award winner. It
should be finished in early spring. Here are
some specifications for this bike. fabrication: Denvers Chopper, Henderson,
Nevada, Motor; 80 inch HarleyDavidson, transmission: 6-speed,
primary drive: Primo Brute IV (not
shown in these pics, Frame: 43
degree rake, Fork: Denvers
springer. I hope you can use these
pictures.
Jack Ryan
Tempe, AZ
“HASSLE - FREE”
Lifter & push rod upgrade for Pan & Shovels
Sifton is the original “high performance” after market
manufacturer for all Harley-Davidson Big-Twin motorcycles since the 1940’s. There is no substitute for experience! These lightweight, super-strong push rods are
manufactured from 7/16” 4130 chrome-moly with a wall
thickness of .065”. They can be adjusted short enough to
install & remove without tampering with the lifter blocks
or rocker covers when installed with Sifton’s “short reach”
lifters. Kit installation reduces the severe angle of the front
exhaust push rod and eliminates the potential of the push
rod to rub on the inside of the cover. Can be used with
seat pressures up to 200 pounds (closed valve.)
Part number 4560 Kit for for Panhead
Part number 4561 Kit for for Shovelhead
Short Reach Lifters only ...........4670
WE PIONEERED THE BIG-TWIN
HIGH PERFORMANCE AFTER MARKET!
56
Send your in focus, correctly exposed (or trashy no-good photos if they have artistic merit) riding photos (rigid
frames only please) to HARDTAIL Magazine, 2621 Green River, Suite 105 Box 389, Corona CA 91720.
943 Bransten Road, San Carlos, CA 94070
57
(415) 592-2203
TWIN CAM-88B
What’s the big deal?
the official
Harley-Davidson
press release tells the
whole story....
ALMOST
HARLEY-DAVIDSON
INTRODUCES
TWIN CAM
88B MOTOR
Counterbalanced Big Twin to
Power 2000-Model Softails
MILWAUKEE… Perhaps more than any
other marque, Harley-Davidson motorcycles have been defined by their V-Twin
engines. The unmistakable look, feel and
sound of a Harley-Davidson V-Twin has
been the cornerstone upon which many
great motorcycles were built. Last year's
Twin Cam 88 turned the conservative
into a foundation and the new counterbalanced Twin Cam 88B completes the
structure.
The Twin Cam 88B was designed in a
parallel program alongside the critically
acclaimed Twin Cam 88 introduced in
1999. Twin Cam 88B carries over many
key components, and will be built on the
same assembly line. In fact, above the
cylinder-base gasket, the two 88s are
nearly identical.
The 45-degree air-cooled Twin Cam 88B
features the same 1450cc displacement
with identical bore and stroke as the Twin
Cam 88. It breathes through the now
familiar Twin Cam 88oval air cleaner and
single 40mm CV carburetor and utilizes
a single-fire ignition system for improved
performance, just like the Twin Cam 88.
It's below the base gasket where things
get interesting: There the Twin Cam 88B
58
features twin counter rotating balancers
to fully cancel primary engine vibration.
The balancers, tightly packaged within
the engine, dramatically improve the
rideability of the rigid-mount Softail models. The counter-balanced Twin Cam 88B
allows for the true long distance in riding
comfort Softail owners have asked for.
Thumb the starter on a Twin Cam 88B
nestled in its rigid-mount Softail frame,
and you'll notice immediately the almost
eerie lack of primary vibration. The
renowned Harley-Davidson sound is
there, transmitted nicely through a new
free flowing exhaust system with
enlarged mufflers (and relocated or
reduced size lower exhaust interconnects on most Softail models) but the
feel is quite different.
Of course, The Twin Cam 88B improves
the 2000-model Softails versus the previous Evolution-powered models much
in the same way the Twin Cam 88 did for
the 1999 Touring and Dyna models. The
Twin Cam 88B delivers the power and
torque enthusiasts have come to expect
in the new Harley-Davidson engines.
Snick the Twin Cam 88B into gear and
you'll notice another big difference: a
50%
reduction in shifter effort courtesy of a
new shifter mechanism and new transmission case.
The Twin Cam 88B is finished in black on
black for the FXSTB, silver for the FXST
and black and chrome on all other Softail
models. The new, larger oil tank features
a new design that reduces the welded
area by 70% to enhance styling.
Additional styling details include new
chrome external oil lines, reminiscent of
such classics as the 1941 FL
Knucklehead.
Harley-Davidson Motor Company, the
only major U.S. - based motorcycle manufacturer, produces heavyweight motorcycles and a complete line of motorcycle
parts, accessories and general merchandise. For more information, contact
Harley-Davidson's
website
at
www.harley-davidson.
Right: pictured is a single
bob-weight used in the
counter balance mechanism
HARDTAIL
MAGAZINE SAYS......
by Buck Lovell
Even if you hold your nose in disdain every
time a non-rigid motorcycle motors by, you
gotta give Harley-Davidson some credit.
They have finally produced a motor that is
perfectly suited for rigid frame applications,
even though it may be a while before it’s
available without the chassis. At least any
with the new “B” motor. My wife Traci, bless
her heart, is the extremely proud owner of
a brand new 2000 Harley-Davidson Softail
purchased from Victorville HarleyDavidson, in Victorville, California. I managed to talk her into letting me “test ride”
the dern thing (25 miles) and I was very
impressed. It is almost completely vibration
free, I mean really smooth. My very first
thought was “This would make a very good
motor for a rigid frame bar hopper.” I suggested this to Traci, but the look on her face
said “go jump inna lake.”
Harley-Davidson is not yet selling the “B”
motor separately, you must buy the whole
motorcycle. Sooner, but probably later I
would think, the Twin-Cam 88 “B” motor
may be available on a stand-alone basis.
The new Softail is really all new. Handling
has been improved at least 200% with
high-lean angle cornering much improved
over preceding models. No, I haven’t sold
out to the other side, rigid frame motorcycles are still my favorite form of transportation, but readers will appreciate this information. The new Softail chassis is the best
handling Big-Twin motorcycle HarleyDavidson has ever offered to the public. I
don’t know exactly what changes were
made to the chassis, but they were effective. For me at least, the Twin-Cam 88 B is
the motor I’ve been waiting for, smooth and
powerful with traditional V-Twin styling.” The
Twin-Cam 88B is without a doubt the most
innovative American motorcycle engine
ever, bar none. But that’s just my humble
opinion.....
Above: Cutaway photo shows Twin-Cam 88 B cases with
counter balance assembly in place.
Below: Cases without counter-balance mechanism.
Above: Massive, over-engineered lower-end
bearings can take a lickin, and keep on tickin.
Reliability has taken a millennium leap forward.
EDITOR
59
Church Bike
r AT
y
t
r
o
sp
A “Classic “Beehive” tail-light (VL era) keeps anyone outback bathed
in ruby red light ( at least at night), and also adds a touch of class to
this genuine Harley-Davidson rat machine.
Some riders carry a comprehensive collection of tools just is
case they might have a need for them, Cory carries this
”special tool kit” because he KNOWS he gonna needem.
The left side looks as good as the right, so who cares which side we show first, huh? This rigid frame rat
Sporty has more class than 10 billet barge Softails, and it gets ridden more too!
By Buck Lovell
Photos by Buck Lovell
Big-Twin snobs who think Sportsters
should never have been invented will consider this motorcycle another example of
why not to like Sportsters. We think it is a
precious jewel in the cap of motorcycling.
Cory Thomas, owner rider loves his motorcycle and rides it farther and more often
than today's "new breed" of rider (another
motorcycle publication claims to be "written
exclusively for the "new breed" of rider).
Cory rides to Church, the grocery store,
around town, and all over the place, not
caring a whole lot about the way the bike
looks, but more importantly how it runs. Not
60
"runs" like in drag racing, but "runs" as in
will I get home tonight? The wiring is all out
in the open for quick fixes, and the paint
can be touched up using Krylon flat-black.
Rustoleum would probably last longer, but
why switch now? Iron Head Sportsters are
considered Classics by a segment of the
Harley-Davidson crowd, with "Rat Bike"
Sportsters few and far between, although
some urge us to believe all Iron Heads to
be junk. We hesitate to call this motorcycle
junk, because we wouldn't want to hurt the
feelings of the owner, so we call it a rat.
Does your bike look better than this Classic
example of American motorcycle iron? I
venture to guess most bikes do, if not, your
machine may qualify as Hardtail
Magazine's next Rat Bike feature.
Pick a theme and stick with-it, good advice
when constructing a custom motorcycle.
But where did the bondo go?
Stock Harley-Davidson brake still functions as when new, absolutely
crappy! You just wish could could stop fast......................hey, how
about new shoes?
Let’s see, the manual says “adjust the clutch cable until there
is 1/8” play between the clutch cable ferrule and the clutch
handle bracket. What’s a ferrule?
61
ABOVE:
Custom wiring is easily repaired on the road, as most of the wire was picked up on the
side of the road. Mechanical brake is as reliable and easy to maintain as any modern
brake, but why bother, it works. If it ain’t broken, don’t fix it!
BELOW:
Magneto ignition is sometimes easy to start, and sometimes requires prayer. Maybe this
motorcycle is the reason Cory rides it to church? Say-what? Note careful lack of billet aluminum or other RUB features. And lookee, the push rod covers don’t leak. Well, they don’t
leak a lot except when ridden hard.
From the “in the wind” wiring, to the oil-sand-dirt-crude stain on the front exhaust pipe this bike says “RAT” in capital letters. When I asked the owner Cory Thomas what brand of carburetor was being
used he said, “I don’t know anything about motorcycles, I just ride this one.” No kidding Cory, who’s your mechanic, Gilligan? Don’t laugh folks, this bike is paid for, thank goodness. If you don’t like
what you see, you either don’t have a sense of humor or you ride an imported piece of crap. This is truly a work of RAT ART. Oh yeah, Cory told me he lost the key to that super-lock on the front of
the bike so now all that chain-and-lock are decoration with no functional value whatsoever! Could this bike be restored to pristine new condition by an expert mechanic with unlimited funds? NOT!
62
Dual plugs? Yeah, one per cylinder. Single Fire? Take a wild guess. Chipped cylinder fins
indicate unavoidable motocross experience (crashed in the dirt maybe?). I like it!
63
LOOKING BACK
mild
WILD!
from
TO
YOUR ONE-STOP
CHOPPER
FRAMES
SHOP!
TANKS
A FLASHBACK TO THE SEVENTIES, WITHOUT THE ACID!
OIL BAGS
SEATS
FENDERS (W OIL TANK)
WHEELS
and much much more!!
John Ventriglia, VP of Primo Belt
Drives has been a chopper rider
for a long time, here’s the picture
to prove it. One would hope that
the motorcycle he is seated on is
equipped with one of the those
early Primo Belt Drive systems.
Rough riding it was, what with no
radial tires, or at least no highquality radial tires. In some cases
riders would resort to the use of a
car tire with more cross section,
just for comfort. This did not add to
already cheesy handling of choppers. But that’s the way it was way
back when.
John Ventriglia is seen (first rider on the left) with some of this riding buddies and other
riff-raff on the sand at Pismo Beach, California in the early 1970’s. Of the old photos I’ve
seen it seems to have been popular to have a police vehicle or cop parked in the background. Dig those crazy solid front fork thangs.
64
CHOPPERS
are back!!
and so are we.
we!
RIIG
GIID
DF
FR
RA
AM
ME
ES
S
R
EX
XT
TE
EN
ND
DE
ED
DS
SP
PR
RIIN
NG
GE
ER
RS
S
E
SP
PR
RIIN
NG
GE
ER
RF
FR
RO
ON
NT
TW
WH
HE
EE
EL
LS
S
S
WIIT
TH
HB
BR
RA
AK
KE
ES
S
W
CU
US
ST
TO
OM
MR
RE
EA
AR
RW
WH
HE
EE
EL
LS
S
C
DENVERS Springer,
hub, and bracket, with
PM disc brake.
1000 Stephanie Place, Henderson, Nevada 89014 (702) 450 0169
fax (702) 450 0170