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Kiwi Classic Leaf Spring Forks - Tech

Made To Order
By Ernie Lopez
Photography by Ernie Lopez
Kiwi Classic Leaf Spring Forks
1. Kiwi Classic Leaf Spring... 
   
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Kiwi Classic Leaf Spring Forks
1. Kiwi Classic Leaf Spring Forks.
Kiwi Classic Leaf Spring Forks Roll Bender
2. To get started, pieces... 
   
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Kiwi Classic Leaf Spring Forks Roll Bender
2. To get started, pieces of raw stock steel tubes were cut to size, then placed in the roll bender. The bend and just how much was a secret.
Kiwi Classic Leaf Spring Forks Frame
3. To get started, the crew... 
   
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Kiwi Classic Leaf Spring Forks Frame
3. To get started, the crew needed to find out what size to build, so the frame was put on the lift. They then used a lift jack to get the frame to sit level. After the rear wheel was put into place on the frame the guys took measurements to find the height to keep the frame level. A four-over stock length was needed.
Kiwi Classic Leaf Spring Forks Leaf Clamps Axle Mounts And Rockers
4. Lucky for us, almost all... 
   
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Kiwi Classic Leaf Spring Forks Leaf Clamps Axle Mounts And Rockers
4. Lucky for us, almost all the other pieces needed to build this frontend were already cut and bent. The leaf clamps, axle mounts, and the rockers were all pre-machined; it was just the length of tube (arrow) that needed to get fitted.
Kiwi Classic Leaf Spring Forks Axle Mounts Placed On Jig
5. To start, the axle mounts... 
   
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Kiwi Classic Leaf Spring Forks Axle Mounts Placed On Jig
5. To start, the axle mounts were placed in the jig and TIG-welded to the front leg.
Kiwi Classic Leaf Spring Forks Neck Stem
6. Then the neck stem was... 
   
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Kiwi Classic Leaf Spring Forks Neck Stem
6. Then the neck stem was jigged for the leaf spring plate. We can't show the whole jig; Mike has a patent and did not want to show everything.
Kiwi Classic Leaf Spring Forks Clamp
7. Once the main support... 
   
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Kiwi Classic Leaf Spring Forks Clamp
7. Once the main support frame was welded together, it was placed on the frame to make sure it was the right size and would house the tire. The top neck clamp was placed on the frame to hold the frontend in place
Kiwi Classic Leaf Spring Forks Spring Support Rods
8. Then the six-piece leaf... 
   
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Kiwi Classic Leaf Spring Forks Spring Support Rods
8. Then the six-piece leaf springs and lower spring plate was bolted to the frontend with the spring support rods (arrow).
Kiwi Classic Leaf Spring Forks Front Wheel
9. Next the front wheel was... 
   
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Kiwi Classic Leaf Spring Forks Front Wheel
9. Next the front wheel was slid into place to check spacing and clearance. At this time the crew could make a few adjustments to the height. If needed, the rocker could be flipped and lower the bike an inch or so. Kiwi offers a few different sizes of rocker to help with perfect fitment.
Kiwi Classic Leaf Spring Forks Wheel
10. The rocker was tightened... 
   
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Kiwi Classic Leaf Spring Forks Wheel
10. The rocker was tightened down and the wheel was placed in the frontend.
Kiwi Classic Leaf Spring Forks Cool Roller
11. This is where we left... 
   
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Kiwi Classic Leaf Spring Forks Cool Roller
11. This is where we left off-with one cool ass roller. We can't wait to see how it turns out.
Kiwi Classic Leaf Spring Forks Mike Tomas
12. Mike Tomas of Kiwi offers... 
   
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Kiwi Classic Leaf Spring Forks Mike Tomas
12. Mike Tomas of Kiwi offers a lot of different sizes; however, he does not recommend them if they are too long-it takes away from what makes the leaf springs work.
Kiwi Classic Leaf Spring Forks Bikes
13. Here is one of the bikes... 
   
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Kiwi Classic Leaf Spring Forks Bikes
13. Here is one of the bikes he rode across Death Valley and then some

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