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Photo journal of the build process of another modified Buell

Rolled Morph

In the following pages Allen Bros Chopper Works will be building a radical pro-street custom frame. Here, we are building our most radical frame yet.

This frame is designed and built from almost all rolled tubing. If you've ever worked with the stuff, you can really appreciate how much work it takes to get things "straight".
Very difficult when none of the tubing is straight to begin with.

The Rolled Morph will take the stock Buell swingarm, and the engine will be rubber mounted (like it's donor bike, the Buell). We're using parts from a 2001 S1 Lightning.

Eat your heart out M.C. Works...

 


 
We designed the basic frame idea in Cad, and had the swingarm plates cut on the waterjet, milled, and planed.
We also took the 1.25" and 1.75" tubing down and had it rolled to specifications.
 
 
Since the frame will use the swingarm and suspension from a Buell S1, we installed and centered a Buell swingarm in the jig.
We put the shock in position and installed the swingarm plates.
 
 
Here's another view of the rear section in the jig.
 
 
The temporary neck post and curved single downtube are positioned up in the jig. We'll be using a 38 degree rake for this frame.
We're also using the S1 engine for this prototype build, to make sure everything fits and flows. 		 
 
Doug fits in the single bottom frame rail into position.
We're using 1.75" DOM tubing with .120" wall for strength (and looks).
 
 

Now the double curved backbone tubes are placed into position
to get a look at what we have to deal with.

 
 
It's going to be fun getting these babies "straight"!
 
 
We then bend up the seat rails and mate them to the backbone tubes and swingarm plates.  

 
The rolled upper backbone tube is mitered to fit and tacked into place. this mates the double backbones to the neck post. Not bad 'eh?
 

(click next page for more photos)

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Contact for questions or comment:
TROY at Allen Bros Chopper Works
DOUG at Allen Bros. Chopper Works