TECH
WORDS AND PHOTOS: DAVID ROE
FIRST -TIME
SKILL LEVEL // MODERATE
BUILD TC BROS. HARDTAIL CONVERSION
PART II
W
ith the frame welded it was mock-up time! Here is where you start putting together all the different ideas you have had on how you want your ride to look. I wanted my ride to be aggressive yet smooth and clean. You need to begin with getting your mounts set up and tacked into place for the oil tank, seat, rear fender, struts, battery box plate, and gas tank. I decided to purchase a 120-volt MIG/Flux cored welder from Harbor Freight to accomplish this and save money. Most welders work by the hour, and it takes a great deal of time measuring and making sure everything is level and in a desired location. This would add up real quick if you did not do it yourself. The investment in your own welder will pay itself back several times over. Note that I just tacked the parts in place. Final welds are done later after you have your bike mocked up. I would only recommend a 120-volt welder for tacking. It just does
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not have enough power for a full weld with steel this thick. Once you have these key components in place, the build really starts to become exciting. Pay attention to detail and take the time to do some extras. I took the pulley cover and cut a large portion away to expose the pulley. An RSD cover enhanced the look even further. Since I decided to have no front fender, I ground off the fender mounts on the lowers and had them lathed out for a smooth finish. The stock wheels were pitted and tired looking. Purchasing new wheels was out of the question. While I was originally dismantling the bike I not only had the wheels but also the rotors and rear pulley powdercoated gloss black by Sumax. The results were incredible! They looked better than brand new with the sleek blacked-out look. A small lightweight Antigravity lithium battery saved space and allowed for extra room in the battery box to hide away unsightly wires. A Joker Machine air
SUMAX POWDERCOAT
Wheels, rotors, and pulley are back from powdercoat. Sumax was the first to specialize in powdercoating motorcycle parts. It does high-end quality work with an outstanding finish.
REAR FENDER CUT
The TC Bros. rear fender comes as a full 180-degree spun piece allowing you to cut to any desired length.
REAR FENDER HOSE AND SPACERS
To keep fender-to-wheel spacing consistent I duct-taped a garden hose around the tire and used half-inch wood spacers on each side of the wheel.
