Monark Style Forks

I have been remanufacturing Monark forks for my builds.  Felt makes a beefier modern fork that looks similar to the Monark and they call it the Abraham Linkage fork.  Problem is people can't use it on vintage builds as the newer fork uses a 1 1/8" threadless stem.  Vintage bikes require a 1" threaded stem.

I am in the process of modifying these newer forks to the 1" threaded stem.  It will take a bit of machining from this point and I should have the first test unit ready soon.  These are going to be so cool!

BTR Seat Cover

I finally got around to improving the cover on my BTR seat.  I gave a local upholstry shop a bare steel pan and a bunch of pictures of original boardies.  Here is what the shop came up with.

Once mounted the new seat gives the bike a heavier and more filled out look.  I have brass badges coming which will mount to the rear of the seat and carry the Sportsman logo.

Heavy Duty Drum Brake Hubs

I have been having trouble getting the correct tooth count and offset sprockets for the large drum hubs I use.  Finally I just had them made.  These sprockets use an adapter plate that carries the drum brake bolt pattern and then I went with split sprockets to make gearing changes easier.  The split sprockets use an standard bolt pattern used in Kart and Jr. Dragster racing.

Here are the hub components.  Stock sprocket is shown to the left, adapter in the middle, and new split sprocket on the right.

Here is the hub assembled with the new adapter and sprocket.  Also shown is the bicycle side freewheel sprocket.

Revised BTR Handlebars

I have continued to improve my BTR style handlebars and here is the latest version.  It took awhile to settle on the right combination of parts to get the vintage Indian motorcycle shape I was after.

The handlebars are aluminum and the drop bar clamps are CAD designed and CNC machined out of billet aluminum.  These bars are light weight and very strong.

Here is a close-up detail of the drop clamps.  The CNC machine work is perfect!  Bars are available in silver powder coat or black. 

Vintage Green

Just built up this nice Sportsman Flyer model using a vintage Harley green color. 

Loop frame with weld-in engine mounts for a 66cc Grubee engine. 

Detail shot of my latest billet aluminum BTR style drop bar clamps for the handlebars. 

Rear wheel detail shot showing the Worksman aluminum rim with a satin silver annodize finish.  Also shown is the latest version of the Sportsman HD sprocket adapter. 

Racing Improves The Breed

The Sportsman Flyer company participated in the recent Willow Springs motorbike races.  Our street gearing kept us out of the winners circle, but we still had a great time and learned a lot about our Racer model.  Bikes handled nicely as seen by Skip, our number 1 team rider.  Nice lean angle, Skip!

What we lacked in speed on the track we made up for in the looks department.  We won BOTH 1st and 2nd place in the bike show.  I was more than happy about that!  The blue bike, our prototype Racer took 1st place and our factory R&D bike, the raw finished chassis #5, took 2nd place honors. 

These two bikes belong to a friend of mine, Doug.  They are beautifully detailed vintage Schwinn Panthers and are running Sportsman Panther tanks and reinforced Monark forks.  Nice builds, Doug!

More WZ Flyers

Here are a couple pictures from our coming website photo shoot. 

Sportsman WZ Flyers

Here are a couple WZ Flyer chassis getting ready to ship.  These will each be getting a jack shaft kit to drive the rear Nexus internal geared three speed hub.  Jack shafts will be installed by the customer. 

Black Racer

A Sportsman Racer in a fresh coat of black powder coat.  This bike came out very nice and is a good example of what a solid design and standardization of components can achieve.  This bike kicks ass!

Indian Red

Pictures of an Indian red Sportsman Racer awaiting final assembly.  All this one will need is the wheels, tires, and controls.  Looks like a fun project for someone to finish up.