.

Mods on Phil's tank

2012-01-27T15:01:00.000-08:00

Had to patch that big square hole left from removing the tunnel on this Cole Foster repop tank.... aaaand move the filler. The bones of the tank are done, just need to add all the other bits.

PQ

2012-01-27T14:58:00.000-08:00

PQ doing what he does best.

Jerzey

2012-01-27T14:51:00.001-08:00

Went last year and had a blast. I will be attending again for sure.

cut-n-patch

2012-01-25T15:57:00.000-08:00

A little more finish work and we'll be good to go.

Making something out of something

2012-01-24T13:51:00.000-08:00

The air drive unit modified for a new planishing hammer and the mount that will attach to the frame... soon.

Dennis F's Triumph project

2012-01-20T17:57:00.000-08:00

Dennis made his way to the shop from NJ last Monday to drop off his frame for some additions and subtractions.

some stuffs

2012-01-20T17:23:00.000-08:00

Cleco E5 aircraft riveter, sheetmetal separation spoons, and a single countersink. One will power the new planishing hammer, one is something a sheetmetal fabricator should never be without, and hell... you know what a countersink does.

Are you kidding me?

2012-01-20T16:47:00.000-08:00

Ordered some bits. They came in the mail. This is the size of the box these parts came in. It's amazing how some peoples brains work.

Another rough mocking

2012-01-19T05:18:00.000-08:00

Got to the next step on the aluminum fairing for the ironhead project. Next will be deciding what shape this thing will really be taking, what will be added and what will be subtracted.

one through four

2012-01-19T05:15:00.001-08:00

Beginnings

2012-01-17T04:19:00.000-08:00

Todd's sporty

2012-01-14T07:22:00.000-08:00

Todd O. sent me a pic of his sporty pre-paint with the bars I made for him. Can't wait to see it all painted up!

Stainless lowboys

2012-01-11T13:09:00.000-08:00

I've been unhappy with my previous decision on handlebars on my ongoing ironhead build, so I decided to take a swing at something new. I have no idea how to classify these but I'll call them "lowboys" just to keep track of the design in my mind. I'm really happy with these, they're extremely comfy and I think they flow better with my vision of the bike's overall aesthetic. I'm going to make a couple set's of these to sell too.

New stuff...

2012-01-11T04:34:00.000-08:00

... added to the store.

Fabrication stuff
-stainless handlebar straps, 3.5" on center with 1" holes on each end so you can use them as a support for your uprights or as uprights themselves.
-stainless handlebar uprights, 1" holes 4.5" on center with a center cut detail.
-1" coped mounts with 5/16" hole, mild steel (use for mounting anything you can dream up).
-battery boxes in stainless, 2 sizes. Un-bent or welded for you.

Bars
-moto bars in stainless 1" thick walled tubing.

moto style

2012-01-11T04:24:00.000-08:00

Moto style bends and knurls in stainless 1" tubing. As far as aesthetics go, these were made for wideglide trees but shown on a narrowglide tree. Available in the store later today.

I'll be playing with some more bend combos soon.

The line

2012-01-09T15:04:00.000-08:00

The line. Anyone who has ever enjoyed building things has crossed it at some part in the journey we call creation. Spending an obscene amount of time trying to get something just right... or at least how you see it in your mind. There could've been ten different ways to go about solving a problem or completing a task, but we choose one.

Made an exhaust mount... took me 3 1/2 hours and used the equipment below.

-tig welder
-lathe
-bridgeport
-angle grinder w/ multiple wheels
-angle die grinder w/ multiple wheels
-files
-pedestal grinder and buffer

I crossed the line today... and wouldn't have it any other way.

Roadside

2012-01-09T14:52:00.000-08:00

Spied this Sunday am while walking the dog. Saw some potential in this free cabinet, so I headed to the shop to add some mid-century flavor to it's 70's era construction.

Front exhaust mount

2012-01-07T13:24:00.000-08:00

Check one more thing off the ironhead to do list. Re-purposed exhaust clamp, half of a gas tank mounting strap, some lathed brass, and a three piece clamp.

choppers

2012-01-07T05:11:00.000-08:00

crazy sky

2012-01-06T19:33:00.000-08:00

Crazy colors that you just can't capture on the phone camera.

hose plug

2012-01-06T19:31:00.001-08:00

Seat pan connectors

2012-01-05T06:24:00.000-08:00

I had to figure out how to attach the seat pan with only cold connections and be able to put the locating pins on the tail section after the pan is upholstered.

Seat pan with some rubber isolators

The parts needed and a piece of test sheet metal since I wont be installing them on the tail section until later.

Nut-sert installed.

Locating pin screwed on.

How it works.

I'm gonna...

2012-01-03T15:54:00.000-08:00

... build me one of these. I remember waking up at 5am one morning in the mid 80's to watch Mad Max on the Preview channel before I went to school. This cb750 trike was the vehicle that stuck in my mind all these years and I swear to build my version someday.

Couple new details

2011-12-31T07:13:00.000-08:00

Just a couple pics of the ironhead project progress.

mini led video

2011-12-27T18:08:00.000-08:00

There's a SPCL'79/Barnstorm Cycles ChopCult Metal Shop feature here on making a mini led tail/brake light right now. The video here shows a majority of the steps involved, as the video included in the feature just touches on a couple of the steps. Props go out to Gabe Kajimura @ After Hours Choppers for the construction ideas and inspiration.

My wife rules

2011-12-25T08:00:00.001-08:00

My Christmas gift was extremely unexpected. 2 nights in Boston, The Black Keys and Bruins vs. Sabres. Best wife ever.

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Merry Christmas to all!

2011-12-25T07:36:00.001-08:00

I hope everybody's holiday season is as awesome as this photo.

Thanks to all that take the time to check out my metal mashing and read my ramblings.

Roland Gaucher's Bentley BR2

2011-12-22T06:27:00.000-08:00

Roland recently came into the shop to share his hand machined scale model of a functioning Bentley BR2 rotary airplane engine. The work on this beautiful piece of machinery is absolutely staggering. It took him 2 years/1500 hours to produce the complete engine and the only thing he didn't make was a few of the nuts used. He even made the spark plugs! Talent like this always inspires me.

Clint on a knuckle

2011-12-13T17:17:00.000-08:00

Was over at Cap'n Bawb's house for some Holiday cheer with a chunk of the 50wt crew and ended up watching a couple of Mr. Eastwood classics including "The Gauntlet". I completely forgot about the bike scenes in this movie, since I hadn't seen it in 20 years. Knuckles, pans, and shovels, mmmmm.

Narrow buckhorns

2011-12-13T11:38:00.001-08:00

Made a set of narrow buckhorns for a customer. I liked them so much, I made a second set for back stock. They look wider in the pics than in person.

You can see by the look on Jake's face that he really likes these bars.

Back to it

2011-12-12T16:01:00.001-08:00

Back to making some stainless mini apes for sale in 8" & 11" heights with different sweeps. These bars were always a pain in the ass because of tubing bender limitations, but I've got it figured out now.

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Just playing

2011-12-11T11:02:00.000-08:00

Spent Saturday morning playing with a set of cast risers and some bends.

More aluminum work

2011-12-07T16:02:00.000-08:00

Jake's welding, my finish work. Getting close.

Location, location, location.

2011-12-07T15:53:00.000-08:00

Filler cap tucked out of the way, yet accessible to even the most plump fingers.

Modified

2011-12-07T15:43:00.000-08:00

Jake cut up the cam cover for the sportster project today. One more thing off the checklist.

Where it will go in

2011-12-06T15:46:00.001-08:00

The oil, this is where it will go. Now it needs to find a home on the oilbag.

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Operation mounting earl bag

2011-12-06T15:40:00.001-08:00

Rubber mounts. 2 each, top and bottom.

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Hammerform part 4: the back side

2011-12-06T05:12:00.000-08:00

Something I haven't talked about is annealing the aluminum before you try to form it, so here goes.
-use a dirty acetylene only flame to put a layer of soot on the surface
-change the oxy-acet flame to a neutral flame and heat the entire piece until you make the soot disappear and reveal nice clean alum
-let the alum air cool, and it's annealed

I decided to hammer the back panel of the oilbag, so it's back to the buck.

Fitted

Welded

Top mounts

Italian eye candy

2011-12-06T05:08:00.000-08:00

I have a soft spot for Guzzis

Hammerform part 3: oilbag side/top

2011-12-04T12:53:00.000-08:00

Starting to bend the annealed sides to the form.

I drill some holes in the sides of the oilbag, screws/washers help hold them to the form while tacking together.

Grind a bit of the hammerform away so as not to dirty the weld tack areas with charred mdf.

Mark the tacking areas with the sharpie.

Fully welded.

Cleaned up.

Another mocking.

Acme springer

2011-12-04T12:43:00.000-08:00

We just got the Acme narrow springer in for a customer's pre-unit build, and its totally bad-ass. If you've never seen one of their springers before, I can't even tell you how nice the machining/design/fabrication is on them.

Hammerform part 2: operation ironhead oilbag

2011-12-01T16:45:00.000-08:00

Roll a few beads on what's to be the top of the oilbag.

Top support to hold the aluminum to the hammerform without marking it.

Line up and make an mdf and alum sandwich.

Start hammering. Go slow and even as you make your way around, taking extra care at the corners. Use a plastic faced mallet (or some other non-marring hammer) to keep from marring the surface of the alum too much.

Finished top piece.

Next I'll be tackling the sides.

running wires

2011-12-01T16:29:00.000-08:00

A little more cleaning up and we can run some wires and put the controls on.

Process: making a hammerform

2011-11-27T15:58:00.000-08:00

Take the shape you have in your head (of the piece you want to make out of metal) and make a template on some thin cardboard. Use the template to transfer your shape to some 3/4" mdf and cut it out. In this case I cut multiple mdf profiles out because I want a top hammerform and a wide edge profile to help shape the sides of the oilbag.

Make your first mdf profile nice and smooth on the edges with a sandpaper/block, palm sander, belt sander, whatever you have to do the job. This is so you can easily clean up the rest of your rough cut mdf profiles using a router and a flush cut bit riding on your first clean mdf piece, making them all exactly the same (if you want to be picky). You can hand duplicate these with simple tools, the router just speeds the process up.

Change the router bit to the roundover profile you want and rout the top edge of your top profile. You can hand rasp/sand to round the edge over if you don't have a router.

Screw all you pieces together and you have your finished form, ready to hammer on.

Hmmm

2011-11-27T15:02:00.001-08:00

Re-makes

2011-11-27T11:22:00.001-08:00

Fred @ Fulton Paint Works bought a set of bars from me that ended up being too short, so I made him a new set. Looking forward to seeing how they look on his bike.

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15 hours

2011-11-24T05:14:00.001-08:00

That's around how long it took to get the electrics box to this point. I know you're saying "finish that thing already and take pics of something more interesting", but I'm documenting my path into forming and welding aluminum. I find myself welding steel mostly, and aluminum tig welding is, to say the very least, different.

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My dream

2011-11-22T06:36:00.001-08:00

Spotted this in a parking lot on the way to the shop on Sunday. Absolutely mint.

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Die, die, my darling

2011-11-20T11:01:00.001-08:00

Had to make a set of dimple dies for the press so the nut serts would be recessed in the panel side of the electrics box.

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Hammer time

2011-11-19T11:00:00.001-08:00

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Puzzle pieces

2011-11-18T13:24:00.001-08:00

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Mocking

2011-11-18T08:14:00.001-08:00

Got some cardboard and masking tape fabrication done on the electronics box to determine shape and scale. I think this is pretty close to what the aluminum box will look like.

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Mounted...

2011-11-15T18:48:00.001-08:00

... rubber, that is. Ironhead is one step closer.

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Work van

2011-11-11T06:37:00.001-08:00

Came across this beauty while walking around downtown Brattleboro, VT. Such a perfect work van, I'd never seen one before.

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BCM parts

2011-11-09T14:00:00.000-08:00

If you haven't figured it out already, Mr. Kim Boyle designs/produces some really nice stuff. Go to his site, buy some of his parts, support a craftsman.

Family break

2011-11-09T08:04:00.001-08:00

Time to see family. I'll be back to work soon.

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Todd's build

2011-11-09T08:00:00.001-08:00

Built some bars for Todd, here's a pic of the build progress he sent me. Thanks man!

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Flight time

2011-11-09T07:55:00.001-08:00

Killing time, feeling creative.

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working on stuff

2011-11-02T16:54:00.000-07:00

Got a couple new products we're working on here @ Barnstorm Cycles and SPCL'79 Fabrication. 304 stainless battery boxes (2 sizes) in welded or kit form and 39mm narrowglide stainless headlight ears for Bates style side mount headlights. Both are still going though a little more r&d, but are pretty close to being available.

A couple stash tube bars added to the store

2011-10-28T10:29:00.000-07:00

A couple stash tube bars have been added to the SPCL'79/Barnstorm Cycles store. That is all, over and out.

must stash t-bars

2011-10-27T13:52:00.000-07:00

stash...

2011-10-26T16:26:00.000-07:00

... tube that is.

Marcin's tank

2011-10-26T04:53:00.000-07:00

Per the customer's request, a high tunneled sportster with a pan style fuel shutoff valve. I'm not the first to do this, Kobe @ Ace Motorcycle was who Marcin referenced for the tank build, so props go out to Kobe. A little more massaging and detail work today and the tank will be done.

Jake's knuckle tank

2011-10-24T06:53:00.000-07:00

Jake is a really good fabricator, which is why I was always baffled at why he ran an aftermarket, ugly, non-modified tank on his knuckle. Well, the teasing finally paid off because he started working on a shell that fits his build and the lines of the bike much better.

Todd's bars

2011-10-21T12:07:00.000-07:00

fantastic machine

2011-10-17T17:51:00.000-07:00

I've never met Matt, but it's easy to tell that I like him already. Much respect, beautiful video.

MACHINE from matt machine on Vimeo.

Bottom rail repair

2011-10-15T12:18:00.000-07:00

Old rails were bashed in the front, new ones are grafted in and ready to go. The tech for this process is in Iron Horse magazine issue 141, check it out!

Organize

2011-10-15T12:08:00.000-07:00

Fabricate to store stock for fabrication. The endless circle continues.

Filling holes

2011-10-15T11:53:00.000-07:00

The top tube of this Triumph frame had so many holes drilled in it that it looked like a flute.

Some art

2011-10-13T06:34:00.001-07:00

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Helmet loan

2011-10-13T06:30:00.001-07:00

My old shop space was right next to JEM Cycle. One morning I pulled into work to see an ironhead basking in the sun. Come to find out, a customer of JEM had ridden from Rhode Island to source out some parts for the bike that had been passed down to him from his dad. What he didn't source was what the helmet laws were here in MA before he hit the road, arriving in the parking lot with Worcester's finest pulling in right behind him. After some head shaking and "what are you thinking" comments, a warning was issued and the cruiser headed out for more pressing matters.

Long story short, I lent this dude a helmet and he lived up to his handshake and returned it.

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Sporty build in Show Class Mag soon!

2011-10-10T16:30:00.000-07:00

Ok, Jake and I here at SPCL'79 Fabrication/Barnstorm Cycles have decided to document a start to finish hardtail evo sportster build in the pages of Show Class Mag. The idea for the articles is pretty simple. Show the steps of building a straightforward, no nonsense, hardtail sportster chop that will have a handful of one-off fabricated bits, but also highlight some of the really cool/quality parts available to bolt onto such a project. Basically, make a simple to follow plan for those interested in building such a bike.

There are many out there that have already realized how perfect the evo sportster is for such a build, hopefully this will open the eyes of the doubting masses. Who wouldn't want an affordable, fast, light, and dependable custom bike? I certainly do!

Blown away

2011-10-07T18:00:00.000-07:00

Got a package in the mail today from Jon Watson of Watto Distinctive Metal wear out in AZ and was blown away to find a one off SP79 belt buckle along with the t-shirt he sent me. I had previously mentioned that I dug his work and would love one of his belt buckles, I didn't think he would bang one out for me (but man am I glad he did). The buckle teeters on that raw yet nicely finished aesthetic that I really like. Thanks Jon, I really owe you one!

Micah's CB350, maiden voyage

2011-10-07T17:52:00.000-07:00

Took out Micah's CB350 Cafe for a little rip after some carb/valve/cam chain adjustments. It's almost where I want it to be, just need the seat foam for the tail section.

Two bikes...

2011-10-07T12:32:00.001-07:00

...that rolled into the shop today. Guy's 1948 pan and Scott's 1948 Chief. So beautiful that they make your eyes hurt.

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snow pipe repair...

2011-10-06T11:25:00.000-07:00

... for a customer's vintage sled. Man, these things were thin as hell.

low drop drags

2011-10-06T11:20:00.000-07:00

Keith wanted a new set of low bars, Jake complied.

speedo

2011-10-06T11:14:00.000-07:00

Jake mounted up the speedo on the bars made for Jeffro's shovel build.

Mmmm

2011-10-05T16:54:00.001-07:00

NYC again

2011-10-03T05:43:00.000-07:00

Close friends made it from CA to visit MA and NYC.

Bill's Mods #2

2011-09-24T05:03:00.000-07:00

New arrival

2011-09-24T04:59:00.000-07:00

Jake was sick of paying/waiting to have tires mounted and balanced so... here's the new addition to Barnstorm Cycles. Mounting machine coming soon.

Micah's CB350

2011-09-24T04:45:00.000-07:00

Tail section... check.
Narrowed clubman bars... check.
Lic plate relocation... check.
Simple exhaust... check.

Oh, and cutting the neck off the bike and welding it back on straight so it wouldn't go down the street like a crab... check.

After some wiring, valve/cam chain adjust, and draining the old gas she seems to be running right. Just need the seat

It's a start

2011-09-21T17:32:00.000-07:00

Bill's Mods

2011-09-21T17:21:00.000-07:00

Barnstorm sporty project

2011-09-21T17:08:00.000-07:00

This will be a fun little bike. Info and tech coming soon.

BKLYN!

2011-09-21T03:58:00.000-07:00

Brooklyn Invitational 2011 was a ton of fun. Fantastic vibe, people, bikes. Great job by the White Knights In The House of Kolor, can't wait until next year.

There were a ton of people that I missed and didn't get the chance to catch up with, I blame it on social overload. As usual I didn't take nearly enough photos, here's a few I managed to capture.

Bars for shovel project?

2011-09-20T19:18:00.000-07:00

not sure what we're going to use, but here's a couple pics of some possibilities.

Moving 100 mph

2011-09-16T06:28:00.001-07:00

Here's the pair of sneakers that ended up on my feet this morning. I realize by pair, most would think that would mean they should match. In all honesty I'm lucky they weren't both left feet. Oh well, at least my boots at the shop were a legitimate pair.

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Benders

2011-09-13T05:30:00.000-07:00

Figures that the bending die sets that I have aren't compatible with Jakes bender. Well, mount them both up and get to work.

Shovel project

2011-09-13T05:17:00.000-07:00

Couple pics of the customer shovel build going on at the new Barnstorm shop right now. Jake has been banging this one out, working out the details with the owner. Only small bits and pieces left on this one and it's off to powder and paint.

GRV pics

2011-09-13T04:40:00.000-07:00

As usual, I didn't take as many pics during the Gypsy Run as I should have. Great people, really neat bikes, perfect riding. Thanks to Walter, Fritz, and all the sponsors for making this year flawless.

GRV

2011-09-09T03:50:00.000-07:00

It's here, and I suck for not remembering to post the details of the run earlier. Walter and all involved always do a kick ass job getting the Gypsy Run dialed. Can't wait to see everyone, ride, check out some bikes, and tip a few back!

Shaping up

2011-09-07T12:30:00.001-07:00

The new Barnstorm Cycles shop is getting there. Functional, but still being organized from the move.

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2011-08-31T07:32:00.000-07:00

Victory beer

2011-08-31T07:31:00.001-07:00

Won the playoffs for the Summer Brew Hockey League, time to enjoy some beer flavored water.

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Stuntz...

2011-08-28T11:53:00.000-07:00

... on a blind curve. Seems like a good place to practice them.

Salt Ghost

2011-08-28T11:24:00.000-07:00

I want to see it.

The time is now

2011-08-27T06:49:00.000-07:00

The time has come, the future is now, and all that good stuff. SPCL’79 Fabrication has experienced some growing pains over the last year and will be going through some changes for the better in the immediate future. Being a one man show over the last 3 years has had it’s privileges but growing business and local goings on have opened a door that will increase fabrication and cut down lead time to finish customer orders. That has been the main stumbling point in the shop when things get busy, and now it’s time for a change.

The deal.

I met Jake Cutler by chance at a local art show where he had some bikes and fab work displayed a couple years ago. I had no idea that the local indy shop, Barnstorm Cycles, existed within minutes of my home shop. A few months after that first introduction, the Barnstorm family had become an invaluable resource and close friends.

Now for the meat of the story. Recently, Barnstorm Cycles made plans to move into a larger, stronger, more awesome location on 24 Wall Street in Spencer, MA, and is within days of opening the doors to the new facility. SPCL’79 Fabrication will be moving with them, creating a partnership that will expand fabrication and bike building capabilities, while retaining the customer service level that Barnstorm has been known for. The increase in parts design, fabrication, and head to toe motorcycle service work is on the menu, so get ready to eat.

Updates to follow, be ready for the grand opening.

He's a couple pics of the newly renovated space (and this is only the 1st floor).

This is what being good people gets you, a free South Bend mill.

AF40

2011-08-24T13:22:00.001-07:00