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Bike project Part 1:
In 1996, I built a bike. Bought a wrecked 1980 Harley Ironhead Sportster off of the Cycle Trader. I completely disassembled it and only ended up using the engine, rear sprocket, lower front fork tubes, the 21" front spoke wheel (because it was brand new) and some miscellaneous small parts.
Bought all my parts from JP Cycle out of a catalog. No online shit here. Filled out the order form, sent it and a check in, and waited weeks for my order to come. Did this 4 or 5 times over the entire build.
Put the motor in a custom hardtail frame with 6 in over front upper fork tubes, using the lowers saved from the original bike.
Had to make all brackets and mounts for everything, as I actually pre-built the bike to make sure it was all gonna work and fit together correctly.
Stay tuned for Part 2
If anyone is interested in a journal recounting of a chopper build... #harleydavidson #chopper #evo #shovelhead #panhead #knucklehead
The next bit of the story... in January 2026 I found a rigid frame at a swap meet. It's a Santee, from the 1990's, but it was intended for a shovelhead with a 4 speed transmission (different mount plate bolt pattern from a 5 speed)
But didn't I say that this was supposed to be for a shovelhead? I did! The Evo had the exact same bolt pattern for its engine mounts as the shovelhead. Unfortunately, the top motor mount does not align.
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2. Now I had a running bike, so what's the first thing you do? Tear it apart. But not to build the chopper! I didn't have anything I needed for that yet, I just wanted to learn how this bike works. (Also, pose it with my other bike)
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(1, end) In spring of 2025, I picked up a 1990 FXSTC for $3500. It had 10,628 miles on it (barely ridden in its 35 year life).
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(1, cont) The "Big Twin" Evo was available in the FXS, FXR, FXE, FXWG and FLH model lines. So I went looking for a used Harley from any of those model lines from 1985-1999. The Softail is the easiest to build from, but it took over a year to find a bike that was within my budget
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(1, cont) In late 1984, Harley Davidson introduced the 80" Evo (it was actually 82cui). It fixed a lot of the reliability issues of the shovelhead, provides better fuel efficiency and overall more power. It can hang on the highway.
en.wikipedia.org/wiki/Harley…
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(1, cont) Knuckleheads and panheads are prohibitively expensive for me at this point, so they are off the table.
Panhead en.wikipedia.org/wiki/Harley…
Knucklehead en.wikipedia.org/wiki/Harley…
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(1, cont) So the Japanese chopper community is buying them up at a rate that is causing a direct impact to the American chopper community. Less shovelheads, and they're way more expensive.
Shovelhead en.wikipedia.org/wiki/Harley…
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1. the chopper would be built on a Harley Davidson motor and transmission. But which? Running shovelheads (1966-1984) are getting more and more expensive, while harder to even come by. Like knuckleheads and panheads, there is a huge market in Japan for original motors
A few years ago I decided I was going to build a chopper (motorcycle). In spring of 2025, after about a year of searching in earnest for a bike to start with, I found the bike that would provide the motor and transmission.
2. Now I had a running bike, so what's the first thing you do? Tear it apart. But not to build the chopper! I didn't have anything I needed for that yet, I just wanted to learn how this bike works. (Also, pose it with my other bike)