Finishing details on the 1993 Harley Davidson FXR.

March 23, 2020

The 1993 Harley-Davidson FXR project is nearly complete. All the custom work is finished, and now it is time to actually get the bike started. The S&S 124 cu in. engine is a beast, and is off to Chopper Jon to get it in good running order.

Just love the stock colored tins and enough black on the bike to keep the chrome in balance. This bike is a family legacy and a tribute to its original owner, so the original red was used to tie it to it’s roots. There are a pair of Motogadgetbar-en… — Just love the stock colored tins and enough black on the bike to keep the chrome in balance. This bike is a family legacy and a tribute to its original owner, so the original red was used to tie it to it’s roots. There are a pair of Motogadgetbar-end mirrors mounted. They have a unique polished aluminum mirror that is supposed to never dull due to a special coating they apply. They sure look good with the rest of the motogadget bar controls, speedo, signals and grips.

This was the first time the bike had been rolled out since tear-down. It has been a long process, but this picture shows the lines coming together, and it felt good to see the light at the end of the tunnel.

Jason Small at Linear Automotive did such a good job on the Freebird 57 Triumph paint, it was a no brainer to send the FXR tins to him. His attention to detail and knowledge of original paint schemes and styles make him the go-to guy for British bik… — Jason Small at Linear Automotive did such a good job on the Freebird 57 Triumph paint, it was a no brainer to send the FXR tins to him. His attention to detail and knowledge of original paint schemes and styles make him the go-to guy for British bikes, but he has done beautiful Italian, German, and in this case, American, bikes that I have seen. He also collects, builds, rides and races these bikes, so he can do it all.

The original red color had faded some and was a little more pink. This richer red was the result of computer matching an unfaded part. Always a big fan of red on a bike or just about anything that moves, the owner’s decision to keep it red was a goo… — The original red color had faded some and was a little more pink. This richer red was the result of computer matching an unfaded part. Always a big fan of red on a bike or just about anything that moves, the owner’s decision to keep it red was a good one.

The clutch activator was converted to a hydraulic one. The milled cover goes nicely with the torque arm, even though the arm is 25 years old. Magnum Black Pearl braided stainless lines were used for the brakes and clutch hydraulics. The black and ch… — The clutch activator was converted to a hydraulic one. The milled cover goes nicely with the torque arm, even though the arm is 25 years old. Magnum Black Pearl braided stainless lines were used for the brakes and clutch hydraulics. The black and chrome on the S&S engine was inspiration for the rest of the bike’s finishes, with an emphasis on the black.

The console has a Motogadget m-lock in the front, underneath the leather. It is an RFID reader that activates the bike when a key fob or a rice-sized chip you can sew into a glove is placed in close proximity. There cannot be any metal covering it u… — The console has a Motogadget m-lock in the front, underneath the leather. It is an RFID reader that activates the bike when a key fob or a rice-sized chip you can sew into a glove is placed in close proximity. There cannot be any metal covering it up, so a hole was bored, the reader mounted underneath, and a thin layer of silicone to level it out on top.

With the leather over the RFID reader, it is invisible.

Xtreme Upholstery in Denton, Texas did the leather seat cover. The attention to detail is quite impressive.

Finishing details on the 1957 Triumph Freebird bike.

November 25, 2019

Even though the Freebird was supposed to be done for the Bornfree show back in June, there were small details that still needed to be worked out the last few months to finish the build. Some of the stuff that was done like lowering the gas tank and extending the header pipes to make them fit more securely is not so obvious, but there are a number of new small parts that have been made for the bike. Parts like the air filter, license plate bracket, and the brass transmission filler cap have already shown up in previous posts, but there were just a few more parts needed to get the bike street legal. I was trying to build a more utilitarian bike despite all the chrome and decorative elements it ended up with. Parts like the large seat, tank package rack, rear rack, and panniers are elements not usually found on a modern show-bike but are actually useful for daily riding. When this bike was being prepped for The Goldenbolt motorcycle show earlier in the year, one of the judging criteria was “rideability,” with a road test through Los Angeles downtown. To me, rideability means the bike is capable not just on the performance end, but comfortable as well, with places to carry tools and accessories (in the end, the rideability was based only on the ability to complete a 25 mile course, and the winner was a long front fork chopper with no front brake, hardly my idea of a superiorly rideable set-up.) But all gritching aside, I am happy with the way things turned out, and the bike is comfortable and easy to start, stop, and ride.

The right pannier was finished off with a brass bracket and leather strap to secure the contents. Just absolute necessities.

A rear reflector is necessary to be street legal in Texas, so this glass one was placed into a custom fitting that screws onto the end of the brake rod.

A brass license plate light that attaches to the adjacent frame tube (another requirement for street legality.)

An LED inside makes for a bright and hopefully long lasting light.

The wiring for the license plate light is enclosed in brass tubing

The rear brake linkage was revised, adding a couple inches to the rear arm of the brake pedal, shortening the brake rod a couple inches, and rotating the brake arm on the rear hub so that it is more straight up and down. The revision was to allow mo… — The rear brake linkage was revised, adding a couple inches to the rear arm of the brake pedal, shortening the brake rod a couple inches, and rotating the brake arm on the rear hub so that it is more straight up and down. The revision was to allow more adjustability to the pedal height and improve the leverage on the rear brake arm.

Counter weights to balance the wheels were made from brass and double as a spoke nipple tool.

When the rear brake rod was shortened, the spliced area was stripped of chrome and would have needed to be rechromed, but since there needed to be a stop for the tension spring, a brass stopper that covers the spliced portion was made. A small brass… — When the rear brake rod was shortened, the spliced area was stripped of chrome and would have needed to be rechromed, but since there needed to be a stop for the tension spring, a brass stopper that covers the spliced portion was made. A small brass pin passes through the stopper to keep it in place.

At the land of the Pines Norton Owners of North Texas annual meet, the Freebird took the Best of Show award along with first in its class.

The 1993 Harley-Davidson FXR project is in the finishing stage, with parts headed to paint and powder coat.

Hours spent on final welding and sanding to get the parts ready for powder.

A lot of welding and squaring up could only be done after the bike was apart, like the final fitting of the fork stops and forward controls.

Prepping Z50R's for show and racing at the Land of the Pines Norton Rallye.

October 10, 2019

A first year 1979 Z50R spruced up for the annual Land of the Pines Norton Owners Rallye. It came to the shop for some paint, an engine rebuild, new bars and shocks. In a super busy year, I have passed on most all of the other shows, big and small, b… — A first year 1979 Z50R spruced up for the annual Land of the Pines Norton Owners Rallye. It came to the shop for some paint, an engine rebuild, new bars and shocks. In a super busy year, I have passed on most all of the other shows, big and small, but always try to make this one where there are a number of friends that usually attend. A friends bike here that was promised for this event, and delivered early with what was supposed to be a rattle-can job, but ended up with PPG color matched acrylic. Though the original Tahitian Red was a shade different from this Blaze Red, the fenders were already Blaze, so I went with it. The tank is an aftermarket HondaTB piece that came on the bike. Taller BBR bars and some heavier duty HondaTB shocks make it more adult friendly.

A 1984 Z50R with the yellow number plates came in for new tires and tubes, a heavy duty clutch, and an 88cc bore kit with a race head. Also belonging to a friend, I was edged out of first place in the minibike race at the rallye by this bike. Not th… — A 1984 Z50R with the yellow number plates came in for new tires and tubes, a heavy duty clutch, and an 88cc bore kit with a race head. Also belonging to a friend, I was edged out of first place in the minibike race at the rallye by this bike. Not the worst thing to be beat by the engine you just built.

Though I didn’t touch the wheels, pretty much everything else got the treatment, with a lot of correct zinc plated hardware replacing the mix of screws the bike came with. Someone patched this bike together, with a crankshaft from a later bike, and … — Though I didn’t touch the wheels, pretty much everything else got the treatment, with a lot of correct zinc plated hardware replacing the mix of screws the bike came with. Someone patched this bike together, with a crankshaft from a later bike, and stator and flywheel from an earlier bike. The stator has a lighting coil that can support 6V lights.

The bike broken down for paint. I had the acrylic enamel on hand for another tank painted a while back.

The Blaze Red would be considered orange by most standards, but either way, the color-match is spot on between the 1984 in the foreground and the 1979.

The 1979 clutch basket was the worst I have ever seen, with the center oil slinger filled with a crunchy grunge and signs of burning. Usually I can salvage something from one of these units, but this one was useless. The signs of hammer whacks on th… — The 1979 clutch basket was the worst I have ever seen, with the center oil slinger filled with a crunchy grunge and signs of burning. Usually I can salvage something from one of these units, but this one was useless. The signs of hammer whacks on the clutch basket tell some of the story, but not all. I was told the bike was started and taken around a track till it started making a screeching noise and was discovered to be completely dry in the crankcase! That does not however explain this level of destruction, with quite a long time necessary to get this level of damage. Oddly enough, the bike started easily and shifted fine, and I was asked to just go over it and make sure everything was okay. The plan was to do a new piston and rings with a cylinder hone, and change out the clutch plates, but when I saw this, I suspected the damage was done before the oil-free ride.

This is the oil pump drive shaft. On the right is a correct used one compared to the one in the engine with the teeth on the end of the shaft sheared off. They were broken off by a rust-frozen oil pump impeller.

The 1979 Z5R engine was completely broken down and rebuilt with some low-milage OEM pieces from the same era, and a new piston and rings. Because of the questionable condition of the parts, everything aside from the engine case, transmission, and st… — The 1979 Z5R engine was completely broken down and rebuilt with some low-milage OEM pieces from the same era, and a new piston and rings. Because of the questionable condition of the parts, everything aside from the engine case, transmission, and stator/flywheel was replaced.

The 1979 is a transition year. The very first Z50R, but retaining some gear from the 1972-1978 early soft tails like the wheels and hubs, the rear brake pedal (painted black) and rod, and a similar muffler to the 72-78, leaving off the number plate … — The 1979 is a transition year. The very first Z50R, but retaining some gear from the 1972-1978 early soft tails like the wheels and hubs, the rear brake pedal (painted black) and rod, and a similar muffler to the 72-78, leaving off the number plate on the right side that the later 1980-1987 Z50R models had. The muffler guard appears to be from a 1988-1999 model, but it is fine with the owner for now. The original seat would have had no logos on the sides, this one appears to be a repop. The bike took third place in the minibike category at the Land of the Pines rallye,

and first place went to the 1971 Super 50 Cafe. This bike had not been run in a while and was brought back to good running shape.

One last thing, this 1969 Z50A left the shop with a new owner. The very first Z50 I ever bought, built, or revived. The bike came to me as just an engine and frame, without wheels, a tank, or seat. The engine was given a stock rebuild years ago and … — One last thing, this 1969 Z50A left the shop with a new owner. The very first Z50 I ever bought, built, or revived. The bike came to me as just an engine and frame, without wheels, a tank, or seat. The engine was given a stock rebuild years ago and all the missing parts were located. A solid running and fairly complete bike looking to be a rider or taken to the next level by its new owner.