Flyrite Harley-Davidson Evo Chop

I’VE BEEN mucking around with and riding bikes for more than 35 years. My only transport is a Harley-Davidson Evo Softail Standard, so after it dropped a lifter on a trip to Sydney, I had it patched up real quick. Unfortunately, the writing was on the wall. It was leaking and using oil; the motor needed a rebuild. I was going to need a replacement ride while the motor was in the shop. I stared looking for a cheap bike.

About this time a mate of mine had just started importing some cool bike parts from the States, and with the Aussie dollar doing well, they were cheap. I decided to relive my youth and build a bike instead. Mal showed me what he could obtain from his suppliers. I gave him a list of what I needed and he ordered the parts.

About three months later, Mal rang and said my parts had arrived; from then on every weekend was spent putting it all together.

First up was the frame, a Flyrite rigid, no stretch and 30 degree rake. I cut off the brackets I didn’t need and welded on some new ones before sending it off to be powder-coated satin black. When it came back, it was fitted up with a DNA three-inch-under springer topped with three-inch risers and 10-inch apes.

The front wheel is 21-inch with an Avon ribbed tyre stopped by a Flyrite brake caliper. The rear is 16-inch fitted with a Classic Z pattern whitewall and the brake is Hawg Halter. I machined up the stainless steel brake stay and wheel spacers so everything lined up nicely.

For the foot controls I wanted raw steel, something like the old Anderson pegs, and in Issue #302 of Ozbike, I saw them. They were called Bear Trap, and at the time I had no idea who the manufacturer WCC was. I baulked when Mal told me how much they were. Luckily, though, he located a demo set in Oz at a decent price. I modified the left-hand side to accept the H-D sidestand before fitting them up.

The hand controls are Custom Chrome minus the switch blocks with Flyrite metallic red grips.

Harley-Davidson Evo crate motors were going for under $3000 so I grabbed one and fitted it with a 42 Mikuni and a ribbed hotrod bug catcher. It was meant to fit an S&S so there was a bit of mucking around modifying to make it fit.

The pipes and upswept fishtails were made by Pommy Choppers before being heat-coated silver.

The gearbox is a RevTech five-speed kicker connected to the motor via a BDL three-inch open primary.

After welding mounting brackets onto the oil and fuel tanks as well as hidden strut mounts on the rear guard, I sprayed the lot with acrylic matt black using spray cans. I also sprayed the Monza Red scallops from a spray can that suit the recesses in the tank. Stuart Vimpani did a brilliant job finishing it all off with some traditional pinstriping. Because I had used acrylic and Stuart works with enamel, the striping had to be done in one go  — no wiping off any mistakes.

I machined up an adapter for the knock-off fuel cap as well as a low profile oil filler cap.

To finish it all off, there’s a Bates headlight and a Sparto tailight fitted with a flat lens and a LED number plate light-bar.

I wired it all up, hiding the electrics in the tank tunnel and under the seat, which is a West Eagle metallic red job to match the grips.

It was a great experience building the bike although I nearly chucked it in because of the paperwork. Luckily, I stuck with it and the reward is a beaut cheap chopper that is fun to ride. Thanks to Mal for all his help, Shaun for the pipes, Dean from Hydraulink for the brake lines and oil line fittings, and of cause, Tyne for the sensational photos. 

Words by Daz; photos by Tyne