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’58 panhead | clutch release arm

March 21, 2015

by Matt with No Comment Fabrication Foot Controls Welding

: I started by cutting off the piece I needed from the old clutch arm.

: I attached it to a fresh piece of 1/2″ round stock.

: After it’s attached, I make the bends necessary to clear the top of the transmission.

: Here you can see the bends.

: I cut down the excess stock to where it needs to be.

: All thats left is to drill the hole for the linkage, and the arm is finished.

: I started the linkage by uing a 1/4″ bolt on the clutch arm side.

: I turned down the edges, just for looks.

: The linkage is pretty simple. A bolt end on the clutch side, and a heim joint on the foot control side.

The clutch release arm that came with my bike was bent, and hit the top of the transmission as a result. So I set out to make a new one. I reused the end of the original arm, and made the rest up as I went along. The clutch throw feels great, and the arm no longer contacts the transmission.

’58 harley davidson | the mids

March 20, 2015

by Matt with One Comment Fabrication Foot Controls Welding

: So how do I attach to the frame? I welded one side of each tab to a piece of 1″ solid stock, then heat and bend.

: The 1″ stock has the same radius as the frame rails I’m attaching to.

: I end up with two nice radiuses on my mounting tabs.

: They hug the frame perfectly.

: I made some threaded slug inserts to bolt my new tabs to.

: This is a photo of a slug insert welded in.

: Now, what am I going to put my feet on? I started by bending up some 3/4″ solid stock.

: At this point I have the tab bolted to the frame. I am going back and forth from the bike to the vise, making one bend at a time.

: This is what I end up with. I made each bend contouring to the motor as well as ending up where I think my feet nee to be.

: I am always a fan of reusing parts. I think these were passenger pegs off a sportster.

: I just needed the ends, and the pegs.

: These are some of the pieces I machined for the moving parts.

: Here are all those small parts assembled and attached to the base. Also I used another tab to mount the rear master cylinder.

: I then fabricate and add the rear bake foot control and brake linkage.

: On to the left side. I decided to mount this tab on top of the tube, to clear the primary pully.

: Using the same process as before, I bend up a base. I have to contour to the motor, align with the other side, and clear the primary pulley.

: The second one is always harder then the first.

: At this stage, I make sure everything alined.

: Now that my base is in, I machine the moving parts for the left side.

: I turn down an area for the clutch pedal to pivot on.

: I trim down my base and fit up the new piece.

: Here you can see the shiny part is where the clutch pedal will pivot.

: I weld on the peg end and attach it to the base. Now for the clutch linkage and foot control.

: I formed a tab over a piece of 1″ stock. The clutch linkage will attach to this.

: I burn in a piece of 1/4″ stock and thread the end. The clutch linkage will bolt right up.

: Lastly, I modified the pegs to better fit the foot grips I bought.

: Here is the left side, clutch side, mid-control.

: Here is the right side, brake side, mid-control.

I never really liked forward controls. So I set out to build some mid-controls. After letting it stew for about a week, I had a rough idea of how I wanted to attack “THE MIDS”.

I have to say, I am more than pleased with the result!! The foot controls feel so good!

(check out the photos for a full write up)

’58 Harley Davidson | rear fender

March 12, 2015

by Matt with No Comment Fabrication Fender Fabrication Welding

: I started out with a used fender off some kind of Harley. Then I chopped it, but something seemed unbalenced still. The fender struts!!

: So I chopped them too!! I also added 1/4″ round stock to the edge of the fender, for aesthetics.

: I attached the fender using these steel bungs that I cut, taped, and threaded out of 1/2″ round stock.

: I was really stoked on the way the fender came out.

This is the fender I came up with for the ’58 Pan-Head. Reworking the struts was a good decision! I like how it still has a nostalgic Harley Davison feel, with a custom twist.

’58 Harley Davidson | hinge seat pan

February 25, 2015

by Matt with No Comment Custom Seat Fabrication Welding

: I started with a seat hinge. I mounted that to the frame first. Then I attached the hardware that was going to attach the seat to the seat hinge.

: I then used a combination of solid round stock to make the seat frame. I weld and shape the round stock directly to the motorcyles frame. I do this in order to get the best fit possible.

: Since it is a hinge seat the rear of the seat never gets latched. To ensure the seat doesn’t move around I made fingers on each side that grab the motorcycles frame.

: Time to skin it!

: I made the rear lip of the pan in the slip roll.

: I then place the pan on the seat frame, and start roughing in the pan, working toward the final shape.

: This is the final result!!

: Sweet hinge action!!

: Building on the bike leaves you with a sweet contoured, fitted custom seat pan.

Well, every bike needs a seat! This is how I make mine. I made a hinge seat that way I’ll have easy access to the oil tank at all times.

’78 KZ650 | engine case repair

February 24, 2015

by Matt with No Comment Aluminum Repair Case Repair Welding

I bought the KZ650 years ago. I knew I would eventually have to fix or replace the engine cases, and of course the cracks were right on the threads which made the repair a little tricky. Well the time had finally come. I was in the middle of rebuilding the motor so I figured, why not now. I bolted the cases together, and removed the JB weld that was previously there. I then preheated the weld area with a propane torch. This was my first real test when it came to welding aluminum, so I was a bit nervous. The beads went in smooth with no real issues. I then ground down the welds and re-tapped the threads for the points cover bolts. I was more than pleased with the results!!

The Shop Blog | Swerve Customs

Posts in category: Welding

’58 panhead | clutch release arm

’58 harley davidson | the mids

’58 Harley Davidson | rear fender

’58 Harley Davidson | hinge seat pan

’78 KZ650 | engine case repair