SUPREME COMMANDERS NOTE:We're kicking this off with some 2006 techs. They will give you the history of the Bonne Belle and bring you up to date on this climb to the top of the salt mountain. Hang on.
We’re working like mad dogs to create a roller while Lee and the crew from Departure Bike Works rebuild the engine and transmission. We’re basically building 1940 45 cubic inch flathead, with a handful of upgrades, including the recent 39 mm Sportster front end and PM disc brakes and wheels. We are also planning to shift it to a foot shift bike using Tedd’s cycles mods.
With the help of Larry Settle’s bike shop in Harbor city we machined a Paughco 45 springer stem and pressed it into the late model Sportster aluminum tree. Larry bore a hole in the bottom and taped it ¼-20 so we could install the below Allen and washer to prevent the stem from pulling loose.
We installed Paughco neck cups allowing us to eliminate ball bearings for Timkens. See shot below.
This created a quirky dilemma. The stem was long for a springer. We had a choice to make and an unforeseen opportunity. From Timken bearing to bearing the neck measurement was 6 3/8 inches. We discovered later that today’s Sportster neck is 7 ¼ inch from top to bottom. We could have turned the Sportster stem to 7/8-inch, but we decided to try the springer stem. For one reason, this system will allow us a more secure pinch bolt system above and below the top triple tree.
We took all the re-machined front end parts to Rick at U.S. Choppers so the frame could be checked with both axles in place for the most accurate frame check.
Larry Settle machined chamfers in the springer nuts to slip inside the top triple tree for the most accurate secure fit. We also machined the springer nut down to make the best use of the stem with a nut on the top and bottom.
Above shows the frame with the front end in place. We will fit up a PM wheel shortly and decide if we need to shorten the tubes more. Actually doesn’t look too bad. Using the springer stem lowered it almost 2 inches.
We already have a set of black powder coated lower legs ready. We will probably powder coat the trees black also.
Here’s a close up of the trees in place. After Rick checks the frame, we’re ready to pick it up.
Here's The Frame Report from U.S. Choppers
First, we cut through the frame in several places, making sure to cause as much damage as possible. Actually we're cleaning up an old mess with da grinda. It’s a highly technical and grueling operation requiring skill and tenacity.
Local expert vet and living legend, Fat Paul, bending the frame into place with shear strength using a hardened piece of spring steel which acts as our straight edge. Go Paul, go.
The frame fairy came over night and delivered a fresh straight frame….. straight and true like an arrow. Disclaimer: no heat was used nor animal testing in conjunction with this experiment.
U.S. Choppers
2039 S. Lyon St
Santa Ana, CA 92705
714-546-4699
Appointments Only Please
http://www.uschopper.com/
And now a report from Departure Bike Works, in Richmond, Virginia– Lee Clemens and his crew are responsible for the engine and trans rebuild and hop-up. Fortunately we had a set of performance aluminum heads and an extra front cylinder. Lee is planning to have special cams ground and run two front cylinders with dual carbs.
”I know, I know, better never than late, right,” Greg, from Departure said? “Not a whole lot to report yet. I finally got Klink to come by & take a preliminary inventory of what you sent. He just had one comment…..’You CAN'T put an ELECTRIC START on a Bonneville contender!’
I'll have more soon…..”
Keep It Greasy,
Greg, DBW
I’m pumped. I may pick up the frame tomorrow and then I’m working with PM and a dirt-bike-foot-controls guy to set up the complete roller. Once we fit the tanks with a new petcock they will be shipped to Jim Murillo for paint with the fenders.
Hang on for the tank and sheet metal tech, coming soon.
–Bandit
