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Time again for another Update. Here's the finished, carved foam Template. The next step was laminating a short tube, using a stainless tube as plug. That tube will be inserted into the tank as tunnel, as I'm planning to mount some switches into the tank. Then the big job started...

Why not aluminium?...Mainly because I was curious to try the FRP process once. I might make it in CF later on...But then I'd still make the Lost Foam one in normal glass first and then use that one as plug to make tools for a proper laminated one (which then could be CF) We make a lot of CF...

Never really considered about it. It's actually nice to hand shape the tank, then I can change/adjust while it's on the bike and make sure I get it how i want it. Also i can direct sit on the bike and make sure it fits my legs nicely. Also...I assume that the foam would totally mess up the...

I haven't posted an update for a few weeks, as we had Chinese New Year and I've been on Holidays. But now it's BACK TO WORK! After the work on the frame and swingarm, we started to tackle the fuel tank. To do it a bit different than usual, we decided to make an FRP tank using the lost Foam...

We've been busy again and made a swingarm. The adjusters on the end and the shock mount are CNC cut billet, the rest is the same tubing we used for the rear of the frame. Also we've done some more work to the frame. Added a shock mount and closed the bottom of the main...

Then let's do an update again. First we made some spacers to mock up the swingarm mounts in their final place. We mainly wanted to check at this point if the frame tubes clear the engine nicely. As we don't have a proper 3D model of the engine, that clearance/fitment really need to be...

That's actually pretty common with modern frames... Our machined head stock is stronger than a comparable cast unit, as our raw material is stronger and it does not loose attributes during the machining.

That's a very good point. We're using 6061T6, which is a well defined alloy. You're totally right that Aluminum does not have a clear fatigue limit like for example steel. But the fatigue limit can be described in a curve, through which you can estimate the cycle life of a certain component...

The machined section is certainly stronger than a welded assembly or cast piece of the same dimensions.

Your points in regards the stiffness are certainly valid, no questions there. Also the connection steering-head to swingarm is of course important...But there you can see several manufacturers already going a different route, with separate "frame" sections for these and using the engine as...

Hi Greg, We notched the tube due to a range of reasons. - The diameter of the upper tube is dictated by the required stiffness/strength - The position of the swingarm pivot point is determined, as that engine gives you already the rear engine mount for this. (While it would be also an option...

Actually...the parts will be powdercoated in Black.

Hi Teazer, I'm happy to address this points a bit further... - Cracks through vibrations That engine certainly vibrates a lot. To counter this, we're going with the machined steering head and axle mounts. These are the points where the vibrations are transmitted to the frame. On both parts...

Let's do an update... Here are the finished Axle-Mounts....

It's all 6061T6 Quite strong and easy to work with... T6 is heat treated for better strength. If you weld that, you'll loose a bit of its attributes in the welded area. After the welding we temper the parts once for 2 hours at 210C. That reduces the effects of the welds in the heat affected...

After the first components turned out nicely, the work can go on. The next step is working on the rear section of the frame. We'll be using the rear mount on the engine also as pivoting point for the swingarm axle...Just like the original Sportster does it, too. The very first thing here...

Time for the first Test Assembly. The top tube is 100mm OD Aluminum, tack welded to the machined steering head. On the bottom we did a cut out, to get the engine closer to the frame tube. Right now it's of course still way too long. It'll be cut to size later on.

Test Fitting the front engine mount... And now the Money shot.. Front engine mount, Steering Head and Fork Assembly

After a few hours on the Machine we ended up with this

Once I've finished the design the guys at our shop machined the parts for me. Here are some pictures from the process. First the Steering Head... Now the front engine mount...