Inside The Big Dog Factory

Big Dog Motorcycles, the World’s Largest Manufacturer of Custom Bikes!

Earlier this summer, I had the incredible opportunity to tour the Big Dog Motorcycle factory in Wichita, Kansas. The flight from the Bikernet headquarters was considerably smooth since Bandit let me fly out aboard his private jet. Smooth sailing across the sky, all I could think about was trying to contain my excitement at the opportunity to view the home of the motorcycle giant.

Just as I exited the plane in Wichita, I could already hear the sound of engines firing back to life. I would find out later that the plane had been requested in Florida for Agent Zebra’s annual jaunt to Cuba.

Modest sign on the face of one of the factory buildings.

The face of the dealership in Wichita, Kansas. This building houses many of Big Dog’s historical motorcycles as well as housing it’s management and sales staff. You can wander through the dealership looking at classic Big Dog’s such as Big Dog #1, Armageddon’s Big Dog, and even a discontinued “Wolf”. The place has a very real aura of growth surrounding it.

Big Dog #1, the birth of a legend.

Armageddon’s Big Dog ridden by Michael Clarke Duncan.

The Wolf. You can gaze at the Big Dog’s of the past and it becomes extremely clear how far the company has come in just over 15 years.

The factory was a quick 15 minutes from the airport, set in the middle of Wichita’s bustling metropolis. I half expected to see 200 Big Dog motorcycles parked in the employee parking lot. Instead, I was welcomed by the familiar sight of any factory’s surroundings; tin buildings surrounded by the average assortment of cars.

Employee parking lot.

To tell you the truth, if it were not for the two Big Dog tractor trailers parked in front near the Big Dog Motorcycles sign, I would have driven right past the place. Across the street is their home office, joined by a very well equipped dealership. Before I knew what was happening, I was whisked into, and then out of, Nick Messer’s office, efficiently starting my factory tour with the frame shop.

The naked fender blanks.

The smell of cold-rolled steel is a welcome tickle to my nostrils as we entered the frame shop. I was showed everything from the pipe racks where the frames and backbones were picked from, to the robotic welder laying down the welds on the frames of future Big Dog Motorcycles.

The frame jig where one of the two Robotic Monsters create the Big Dog frame.

The frames go through a quality control process that is second to none. Before the frames can be sent to the next stage, they are meticulously checked for proper welds, measures for proper dimensions, and eyed for any imperfections. Like I said, they are very serious about putting the absolute best product on the market, ensuring each customer will be happy for many years to come.

The Softail-Style frames lined up. This is the beginning of Big Dog’s next litter.

I was a little surprised at the size of the factory. If you added all the buildings together, there is enough space to cover a city block. Because of growth, Big Dog has busted out of the building the company started in, and keeps on expanding to more facilities with Wichita’s friendly confines. It seemed every station of the assembly process was handled in a different building.

TRIBUTE SHOVEL GUTS&BOLTS

ENGINE
Model: Shovel
Capacity: 1200cc
Builder: Ollie’s Engineering & Machinery
Cases: Stock
Crank: Trued and balanced
Bore: 10 thou over
Stroke: Stock
Compression ratio: 8.5 to 1
Bearings: HD
Conrods: HD
Oil pump: Reconditioned original.
Oil cooler: Lockhart
Oil: Kendall
Cam: Andrews (mild)
Lifters: Velvet Touch
Pushrods: Velvet Touch
Barrels: Stock HD
Heads: Long reach spark plug conversion
Tungsten alloy valve seat conversion.
Ports: Ollie did his thing
Rockers: Stock
Valves/springs/retainers: Black Diamond valves
Andrews Valve Springs
Ignition: Crane single fire
Carburetion: Evo CV
Manifold: Stock
Fuel: High octane super.
Air cleaner: S.U.
Exhaust: Custom made ceramic coated duals
Mufflers: Original 1990 Sturgis mufflers
Power: More than enough for me
Maximum revs: No idea
Top speed: No idea (no speedo)
Other mods: Externally mounted oil filter

TRANSMISSION
Year: 1972
Type: Ratchet Lid 4-speed
Close ratio Andrews gears
Gearchange: Original FLH
Clutch: Barnett
Primary drive: Original chain
Rear Drive: Chain.

SUSPENSION
Front: Sonic Telescopic
Triple Trees: FXWG Wide Glide
Extension: 4-in over
Rear: Rebuilt originals by Rad Shocks in Brisbane

WHEELS
Front: 19-in. HD re-chromed
Tyre: 100 x 90 Bridgestone Spitfire
Hub: HD
Brake caliper: Banana Caliper
(It works well)
Brake rotors: Aftermarket
Brake lines: Braided.

Rear: 16-in HD re-chromed
Tyre: 300 x 16 Bridgestone Spitfire
Hub: HD
Brake: Juice Drum Brake
(Also works well)
Brake line: Stock

FRAME
Type: Genuine swingarm
Year: 1972
Model: FLH
Rake: Stock
Mods: None

CONTROLS
Handlebars: 16-in Apes
Grips/levers: Billet grips
Custom leather outers
Risers: 3-in Paughco offset dog bone risers
Master cylinder: HD
Switchgear: HD
Mirrors: One
Headlight: After market
Gear change: Stock
Footpegs: FLH running boards
Rear brake master cylinder: HD
Speedo/tacho: Nope

Other: Oil pressure gauge and oil warning lightTaillight: L.A. County Choprods

GUARDS/TINWORK
Tank: Little Mick
Oil tank: Paughco
Front guard: Cut down stock
Rear guard: Wild Willy
Seat: G.P.Leather
glenn@gpleather.com.au

OTHER
Paint: Satin black

As we drifted from building to building, I tried frantically to get as many photos as possible to give you, the reader, an idea and feel of the manufacturing process. Each station had a different radio station blaring, but you also hear the small talk and laughter you would associate with friends talking at the park. It is apparent that these employees not only enjoy each other’s company, but like the work they do as well.

The sights of the machines being put together right in front of me excited me to no end. From the frame department, we moved onto the engine and drivetrain assembly. Rows and rows of unassembled S&S engines stare at you from the shelves like puppies waiting for an owner at the pet store; each component glistens with style and fresh possibilities.

I was lucky enough to be in the factory during the assembly of the Limited Edition blacked-out K-9. To see this world-class custom come together before your eyes is very surreal. It was amazing the care that was taken from every individual working each station of the build process.

After the engine and tranny were installed, the naked frames rolled along to the wheel department. Because we were there during the end of the 2007 season, we saw only the wheel packages for the previously mentioned K-9.

It was at the next stop- the paintshop- we were treated to the highest level of craftsmanship to bee seen by the naked eye. Rows and rows of extraordinary paintjobs lined the shelves. We were even lucky enough to catch a glimpse of on of the extreme paintjobs available for 2008’s called “The Gate”. Extreme is the only world that could adequately describe this section of the plant.

The level of talent these artists have achieved and developed is extraordinary. I applaud BDM for going after the very best the country has to offer. While one of Big Dog’s top designs may add several thousand dollars to the MSRP, I feel the quality displayed proves it is well worth the dough.

Last section was the final wiring and detail work. Miles of wire lined the rolls just waiting to be extruded onto the next custom. Organization, cleanliness, and a sanitarily clean appearance, Big Dog’s factory was quite impressive.

After touring the factory and taking as many pictures and notes as I could, my wife and I spent the rest of the day touring the town of Wichita. Coming from Houston, Texas, Wichita seemed a small city. We drove around the city that day trying to plan the course for the next two days of riding. A few months back, we posted the story of my rising the K-9 chopper. Stay tuned in the coming week for my review of the very impressive Bulldog.

Overall I have to say I was surprised to discover the overall size of the manufacturing facility. When we walked into their warehouse, we were confronted by hundreds of bikes. Each one whimpering for attention as they all are waiting to tear into the road. The sight was simply breathtaking.

I would like to extend thanks to all the employees of Big Dog Motorcycles. They showed us hospitality and respect that not only made us feel at ease, we felt absolutely welcomed. From the top employee to the very bottom, these guys and gals believe in their product and their company. I have a feeling they will be around for many years to come.