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2020 - 2021 | personal project

Custom Harley Davidson

  • mechanical engineering
  • motorcycling

Being a Motorcycling enthusiast myself, as well as a technically skilled designer, I wouldn't back down for a challenge like this. This Harley Davidson motorcycle had caught fire about 30 years ago, completely destroying the bike. Therefore, making an expensive brand motorcycle suddenly affordable. The catch, however: it needed to be completely restored.

The bike originates from 1989 and started out as an FLHTC (Electra Glide Classic), though since it had to be rebuilt anyway, we had the opportunity to make some modifications, and build a Road King instead. Together with my brother, we rebuilt the whole motorcycle from basically a bare frame, some fenders and the (already refurbished) 1340CC engine. In addition to the essentials, I designed some custom parts to both save money, and to include some custom accessories.

The tank got a complete make-over, as the fuel cap needed to be relocated to make room for the speedometer. Dents and imperfections on the outside of the tank were corrected using polyester putty and a new coat of paint. The inside of the tank was completely rusted over time, which was cleaned out as well.

A similar process was followed for the saddle bags, which did not survive the fire. A pair of unmatching cases was found that needed to be cleaned, repaired using fibre glass and putty, and painted in a matching style with the tank. For the locking mechanism, we had to make some additional hardware too, as those parts were no longer sold anywhere.