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Photo journal of the build process of a modified Buell
Morph666
In the following pages Allen Bros Chopper Works will be building a radical pro-street custom. We will design and build the complete bike including the frame.
The idea is to build a custom chopper that almost anyone can afford.
A "poor mans radical custom", if you will. This bike will be called Morph666, since we are morphing a Buell sport bike into an AllenBros custom. Total build time should be under 2 months, and build cost will be around $7500 (not including labor). The plan is to use as much of the doner Buell as possible to minimize cost.
The Morph666 frame can be purchased by custom builders interested in this sort of project, or we can be contracted to build a similar bike to completion.
Eat your heart out Redneck...
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Ok, this is the doner bike. A 1999 Buell Cyclone M2. This sport bike has eveything we need to build a badd-ass pro-street chopper. It has a 103 HP Thunderstorm engine (which is a hopped up Harley 1200 Sportster Evolution engine). We'll also be cannibalizing the front end, wheels and brakes, instuments and controls, etc...
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To get this project off the ground, we'll need a good drawing with all dimensions and materials list. This is the basic concept drawing of the pro-street frame we'll be using. It's a rigid 2" down 42 degree rake. It'll be built with .120 wall DOM tubing, 1.25" in the frame rails and seat rails, and 1.75" in the backbone and seat post. We'll use waterjet cut steel plate for the "downtubes" and gusset plates. Troy of AllenBros designed and engineered the project.
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Here's the frame jig we'll be using to build the frame. We're one of the only shops in Colorado with a frame jig. It's capable of building just about any chopper frame a guy (or gal) can dream up.
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| We got the waterjet pieces cut to spec, and ordered up the tubing. We also got the rear axle blocks machined on the lathe. Once all the materials are together we can start the build. We also had to make all the mandrel bends in the tubing for the various frame pieces. |
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We started the frame assembly by installing the axle plates and neck post in the jig. Positioning has to be perfect, since this is the foundation for the frame.
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Here the axle post gussets are checked for fit.
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And here's the completed rear section...
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| We position the lower frame rails and downtubes in the jig and tack weld into place. |
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(click next page for more photos)  NEXT PAGE TOP
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Contact for questions or comment:
TROY
at Allen Bros Chopper Works
DOUG
at Allen Bros. Chopper Works
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