aluminum fixes

Here is a neat picture of machining out the two cracked screw holes that we welded up. This is a pretty common repair.

HEre they are finished up!

HEre is one of the kicker covers after being bored out. I milled the surface flat, and there is still some weld on the top that needs to be ground down.

here it is all finished up. This isn't as nice as I did before the accident, but it is pretty damn close

52 fl progress

Woohoo the 52 fl is a roller. This bike came to us as a poorly running mildly fixed up bike. Randy bought it off ebay and rode it two miles, got thoroughly disgusted with it and sent it to us to sort out. We found the right frame for it and have been redoing and fixing the previous workmanship. It won't be a points bike, just a great rider set up to go wherever he wants.


Here is a neat pic with the motor installed. I will bolt it down after lunch. The transmission is almost done, This will be a super nice motor bike. I am excited to ride it in the spring.

Rocket ship stuff

My dad got the flywheels in this 53 fl today.


It was -4 degrees this morning. I took this pic of a frosted tree.



I spent the day finishing up kicker covers and rebuilding some fork tubes for a 52 fl. Everything is pretty nice, I just took it apart and smoothed everything up.




Here is the stuff getting ready to go back together.

42 pictures!

My dad finished up don's 42 motor! this thing is sweeeeet


These are 1940 to 1942 stainless steel pushrod clips that we made up for this batch of bikes. Originals are impossible to find



I love all the contrast in this pictures.




HEre is the transmission that is paired up with the motor!





oh ahhh

42 el and kj stuff

I took yesterday off and hung out with tanya, even though I wasn't at the shop, neat stuff was still happening. we got a set of handlebars for my dad's kj in the mail. This is an original casting with new bars. They turned out great! thanks tom


Here is a neat pic of some strange castings on the set of 42 cases that my dads putting together. check out the extra aluminum on the timing plug and inner primary sleeve. This is from the patterns not being packed super tight when the cases were poured.



this is pretty neat too,




and going together. next up is the cylinders and heads. Should be done today.

aluminum pics

here is my project for the day. These are all cracked kicker covers. I mill out the cracks with a .5 endmill and weld em up.


Then you bolt them to the table and co ax them in line with the head of the mill.



then bore out the hole to the right size.





here are two types of kicker studs. the left one is 46 and later and the one on the right is 45 and earlier. Ray is finishing up the 42 trans today.

here is the pic of the left 42,43 and 44 style of left case that I talked about in the previous post. The top of the case kicks in at a 5 or 10 degree angle at the top. PRettty cool stuff. I love how bright hd aluminum is when you blast it with fresh beads.

early knuckle case pics and motor photos!

This is a really neat detail that not to many people know about. There are two styles of long rib cases. The serial number boss on 42, 43 and some 44s have a recess at the bottom of the pad where it meets the radius of the case. Here is a picture of the front of the pad


and here is a pic of the back. The casting is different on the cylinder base area as well. I will post another pic in a bit.



my dad got the flywheel bearings set, and the end play sorted out. Time to prep for final assembly!!!!




We spot face the bosses where the case studs nuts go. they get kind of worn down after 50 to 70 years of getting rebuilt





OHHH AHHHH shiny! The next step after all the bosses are spot faced is to do one more wash in solvent and water ane prep for final assembly.

42 el motor pics.

I started prepping a 42 motor today, Here is a pic of the right case with no oil pump studs.


Here is our cabinet in the clean room that we write a ton of dimensions down on. You can see the call out for all sorts of different studs, bearing clearances, end plays and other cool stuff. We remove, re plate and replace every stud in every bike we do. It makes the finished product that much nicer.

here is the pic of the studs installed. They are all within .005 of the correct length. check out the short spacer nut which is the same as on a 45. 41 42 43 and some 44 knuckleheads used this nut and it was extended to the later knucklehead and pan head style sometime in 44.

Here is a pic of all of the parts laid out. I have always wanted to take a picture like this. It is kind of like a widespread parts book picture, but with real life parts. There are a few parts missing, but most of it is there. Check out the circuit breaker, they are so damn beautiful

check out the 42 to early 45 oil pump. It is the hardest knucklehead pump to find besides an early early 36 one! This thing should be coming together in the next few days! stay tuned

neat motor pic

My daddy finished up Andy's 47 motor today and added it to the line up. IT is the one on the front left. four down and sixteen to go I love old motors.

site gauge progress and tappet pics!

I was pleasantly surprised to find a half dozen prototype site gauges at work this morning. We have been working on this project for two years and it has been the most challenging piece that we have ever made. The plastic piece was approved 14 months ago, and we have over 20,000 miles on prototypes. Now we are going through the process of sorting out the u bolt, related hardware, instructions and packaging.


The acorn nuts and bottom screw are the most obvious pieces that need to be changed, but there are a lot of other small details that need revision. These are so damn cool, but we have to be 150 percent happy with them before they go to market.



here are two of the three sets of knucklehead tappets that Rock master jesse fixed up for motors we are working on now. My daddy also finished up an awesome 47 motor that I will post pics of later.