We needed to take one last...
We needed to take one last look at the old sheetmetal.
We were thinking that it was time to freshen up the look of our '99 Evo Softail custom as the big look of the old Fat Bob tanks just don't fit the bike anymore.
We wanted to swap out the old sheetmetal to give the bike a whole new look. We called Milwaukee Iron for a set of fenders -- in the rear, we liked the look of the strutless Sheriff rear, and in the front, the smooth lines of the Shark Tooth. We still needed to find a gas tank that looked just as good with these fenders but we weren't having any luck. We discussed the matter with Joe Warren, the owner of SGV Choppers in Covina, California, and he told us that we could just make one and save some time and money. In no time, we got started on slimming it down, to get a real chopper look.
Here are the new fenders:...
Here are the new fenders: the Shark Tooth front and the Sheriff strutless rear fender.
The new M.I. fenders have...
The new M.I. fenders have the struts built in, so the old struts on the frame needed to be removed. First the motor and trans were covered with a sheet to protect them from flying sparks. Warren cut the struts off with a saws-all, then grinded down all the edges with a disk sander.
Warren didn't waste any time...
Warren didn't waste any time stripping all the old sheetmetal from the bike.
With the frame now strutless,...
With the frame now strutless, Joe placed the new M.I. fender on the bike to get a look at just how it sat on the frame, checking the height and lines. The fender looked good as-is, but it was still a little too high for the look we were after.
We also we wanted the fender...
We also we wanted the fender to sit closer to the tire, so we needed to cut off the mounting plates on both sides. This is easier than cutting off the support plate along the front side of the fender, and it allowed us to lower the fender height so we wouldn't have to drill new holes.
The fender was sitting at...
The fender was sitting at the right height above the tire, but its sides did not follow the lines of the tire. So, the guys at SGV made side skirts to fill in the space.
After making a pattern from...
After making a pattern from paper, it was transferred to 16-gauge steel. The shapes were then cut on the band-saw.
Next, the skirts were tack-welded...
Next, the skirts were tack-welded in place to check the shape and look, then Joe welded both pieces to the fender.
You can see how much better...
You can see how much better the fender looks with the skirts and the way it sits closer to the tire
Moving on to the front fender,...
Moving on to the front fender, Joe placed the Shark tooth on the bike. We found that the size was for a 19-inch while this bike has a 21-inch wheel.
The mounting holes would need...
The mounting holes would need to be lower so that the fender would sit higher and have enough space so as not to rub when the tire expands at high speeds.
Warren, marked and cut the...
Warren, marked and cut the mounting tabs, then made a 2-inch piece of sheetmetal to lengthen the tab for proper fit.
He also marked the front of...
He also marked the front of the fender were he would trim a little off to give it the same shape as the rear fender.
Next, Warren started on the...
Next, Warren started on the gas tank. We wanted a tank that fit the look of the bike and was a one of a kind. He called up one of the little-known secrets in the industry, Cad Works in Monrovia, California, to get a set of tank halves that would be cut down and welded together for a custom-made gas tank.
After the Cad Works halves...
After the Cad Works halves were cut from the blanks, Warren needed to trim down both sides to match and fit together before getting welded. The tank sides were placed on the bench for a flat surface then he used a block and a straight edge to mark around the tank in an even line.
The two pieces were placed...
The two pieces were placed together and marked for the proper length he needed to trim from the rear of the tank before it could be welded.
The two pieces were placed...
The two pieces were placed together and marked for the proper length he needed to trim from the rear of the tank before it could be welded.
This tank was getting a custom...
This tank was getting a custom look so a flat-bottom tank wouldn't do. Warren cut out a template to give the tank a curved bottom that would flow with the top of the motor.
Next, the tunnel was marked...
Next, the tunnel was marked and cut to fit the tank.
Warren then cut out bottom...
Warren then cut out bottom panels and welded them to the tank.
A Pro-One pop-up gas cap was...
A Pro-One pop-up gas cap was welded to the highest spot on the tank to get as much gas into the tank as possible.
To mount this tank to the...
To mount this tank to the frame, Warren had to mill down the solid steel bungs before they were drilled and tapped. Then they were welded to the tank and bolted to the tabs on the frame.
Warren drilled out the tank...
Warren drilled out the tank bottom where the bungs would be welded. After all the mounts were welded, the hole for the petcock was drilled but it was not installed.
This is the new look with...
This is the new look with the all the sheetmetal installed, and what a different look it is. We can't wait to see it after paint, so check back next month as we get the sheetmetal covered in some colors.