ULTIMATE FXR BUILD--from Bennett's Performance, Part 2 — Bikernet Blog

A Southern California show, Born Free, is just six weeks away and there is a very special aspect to this show, the FXR competition. Eric Bennett is busting his ass to build the ultimate FXR for this show and the Hamster FXR Show in Sturgis this year.

Bennett’s Performance will post no less than seven shop FXRs into this competition. His shop is devoted to performance Dynas, FXRs and Touring bikes. He’s rocking on this project and we needed to bring you part 2 before he goes to paint. Here’s part 1:

http://www.bikernet.com/pages/ULTIMATE_FXR_BUILD_from_Bennetts_Performance.aspx

He just returned the bike to the shop from Saddlemen where the masters of luxury seating built him a custom fiberglass pan, which will contain a couple of carbon fiber accents. While the Saddlemen team completes this ground-up custom seat with gel technology and racing material wrap, Eric hauled the bike home for additional preparations heading in the snappy direction of final assembly.

Buck Wild has agreed to paint the sheet metal, but I can’t disclose the paint scheme. It’s secret, except to say Eric is all about the mechanical aspects and performance, as you will see. No skulls or knives will adorn this scoot.

“The new age of builders and riders come from a different background,” Eric said. “They come from skateboards, surfing, dirt bikes and ATVs. They like the mechanical.”

The ultimate FXR is semi-complete except for cutting a rear rotor and building his hot rod 106 Twin Cam with mostly S&S components. ?
“Bennett’s buys more 106 kits than any other shop,” said his S&S rep.

?“This S&S kit does the job for the perfect performance Twin Cam,” Eric said. “It’s the only way to go.”

The FXR frame has not been modified for the Twin Cam configuration, but he had to modify the oil pan under the trans to make it fit, and to give the custom Brock’s swing arm enough room to play.

He did remove the stock battery pan and replaced the structural bar from the right and left sides of the frame with something more substantial, which matches the frame tubing size from ¾-inch to 1 1/8.

Also, with the Big Bear mounts on either side of the front of the engine, he eliminated the stock triangle rubber-mount base and replaced it with tubing and a mount for a special Moss battery charging regulator. He is using a fist- sized lithium battery, which demands a slightly different charging system.

Lithium batteries can be charged to 14.4 volts. Chargers have different capacities. A gel battery needs to be charged to 13.8-14.1. If you only charge it to 12 volts, it limits the capacity and life of the battery. We are investigating these issues with Wayne Electric in Long Beach.

Eric finished all the stainless exhaust pipe work and brackets. “I can’t wait to hear this puppy blast down the road,” Eric said.

One of the quirky aspects of this build is the wiring guides. He found these at the Speed Merchant shop, who discovered them at a bicycle shop. The process of hiding and dealing with wiring looms has changed drastically over the years. “I don’t want to use any wire ties,” Eric said. He will use or twist only safety wire around these guides and over his wiring looms. A very cool detail.

Eric just added a super bright JW Speakers, Jeep off-road headlight to his massive 34-inch carbon fiber KTM Super Duke (sport adventurer) front end. It’s 60 mm at the widest point and 55 mm at the top as it enters the billet badass Rebuffini aluminum trees. “They can make any size or width trees in a flash,” Eric said.

The front wheel held a spacing challenge with the Hayabusa front super-light carbon fiber front wheel. Eric had to machine the hubs .085 to move the cool rotors inboard to align them with the dual Brembo brake calipers, which cannot be adjusted in and out, only broader to fit larger diameter rotors. He made the axle. The adventurer 13.2 rotors are bolted in a much stronger configuration due to the spread positioning of the hub, very strong and reactionary.

The rear system turned out to be much easier to deal with, but there still is an issue. Since the Speed Merchant Brembo caliper will adjust inward, Eric wants to run a small 10-inch rotor. “I’ll have all the braking in the world with the front,” Eric said. He needs a small rotor and is discussing the issue with Metal Sport Wheels today. They can make anything.

So far, he’s running a RSD air cleaner with his Mikuni Carb, and since this is no longer fuel-injected, he’s handling the ignition with Daytona Twin Tech. Wire Plus makes a plug and play wiring harness for this configuration. So, yes, you can still build a Twin Cam with a carb. I like it. Although, I’m more excited about the new M-8 engine configuration.

Get this. He’s using a cool Super Sproks sprocket with a lifetime warranty. It’s two-piece, sorta like floating rotors or old mechanical brakes with the sprocket riveted onto the brake drum. I asked about a chain guard and Eric confirmed my old school thinking. I’m a stickler when it comes to judging show bikes. If they don’t have a chain guard, it’s serious points against them.

A chain can do severe damage if it pops loose or breaks, whereas a belt won’t break or miss a master link, and if it does break, it flops on the pavement and you’re done. T-rod is modifying a splashguard, which sorta doubles as a chain guard, “Almost,” Eric mumbled and gave it some thought.

His initial plan is to satin black powder the frame and have it pinstriped with gray details. There will be no triangle panels on the sides of the bike, and he still needs to figure out foot pegs, grips and mirror styles.

His plan is to build the engine and send everything to paint. When he’s ready with all the prepped components, he wants to devote two straight days to assembly. “I hope to complete the meat and potatoes,” Eric said. “I’m sure there will be a handful of details hanging, but I want to be damn close in two days.”

He will use the local performance line and fitting shop, Baker Performance, for his brake lines, and he hopes to work with Rivera on his belt drive. He will order a fastener kit of 6-point stainless fasteners and throw in a handful of Allens. His rear brake master cylinder is also Brembo and he will mount a dirt bike reservoir above it.