Widow Maker Custom Design & Repair "Hazey Thought"

One of the most stunning exhibits at this year’s Capital City Bikefest was the custom-built chopper known as “Hazy Thoughts”. At 11 feet in length, and weighing in at around 700 pounds, this monster is just the latest in a long line of custom built motorcycles to come out of the Widowmaker Custom Design & Repair shop in Rougemont, NC.

“The project began back in 2012”, said Hank. When a gentleman walked into the shop with a vision of a bike he wanted to build. The client went on to tell Hank that as a boy growing up his father had owned several choppers and he wanted something bigger than life like he remembered his father to have had. So, Hank worked with the customer to hammer out the details of exactly what he was looking for, and the build was on.

Hank recommended using the Ultima 107 EVO engine and 6 speed RSD transmission and a 3.35” drag style open belt primary for the power to move this monster. “Bang for the buck, it’s a great motor” said Hank. With the motor in hand and waiting for a frame, the customer searched for one that would get him close to what he wanted and would fit his budget. He located a PMC rolling chassis that was close enough to fit the needs of the build. The frame, was not only not long enough for the client’s vision but also was built for a twin drivetrain. So, Hank had to fabricate new mounting brackets to accommodate the EVO motor and transmission.

Next, came the forks. The fame was built with a 45-degree fork angle but in order to achieve the extreme length the customer desired the forks needed to be mounted at a 67-degree angle. Hank cut and rebuilt the frame accordingly. The original forks selected by the customer proved to have too much weight (as they were 6 ½ feet long), allowing them to twist and flex. Hank reached out to American Suspension and a custom D-66 Dragon springer was made for the bike. Now with the rake and trail

back in check, the pace of the build could speed up...a little. With the 11’ rolling chassis complete Hank was ready to tackle the handlebars, fuel tank and fenders. “The handlebars were easy”, said Hank. “I already had a set that I had made earlier as a static display, and they worked perfectly”. Not as easy was the fuel tank. The customer provided Hank with a full-size template he’d drawn up showing the shape and size that he envisioned, but after fitting a mockup to the frame they realized it just didn’t look right. So, Hank went to work to redesign the tank and after a few test fits they found the size and shape that worked. Building it though was another matter. The new tank required 20 square feet of 18-gauge steel to be cut into 26 separate pieces and shaped to exacting measurements. Each piece was then welded into place using a steal frame Hank built to act as a jig. The tank alone took many late and long hours but the result was well worth the effort.

Fabricating the fenders presented their own challenges. Bending compound curves into sheet metal while keeping everything perfectly symmetrical is not easy, and Hank modestly admitted that it took several attempts with new steel to get it right. There were two front fenders made to achieve the correct look. The oil tank was made into the front of the rear fender to keep the lines of the bike clean.

With the bike essentially complete, Hank outsourced the finishing work to different craftsmen in their respective trades. The seat leather work came from Corey Hughes at Hellbent Creations in the Charlotte area and the powder coating was done by Fletcher’s Powder Coating out of Creedmoor, NC. The spectacular candy purple paint job was done by Mike Miles at Auto Arts Ink, in Raleigh, and the galaxy themed graphics was done by Zach Matthews at ZMCC, also out of Raleigh.

Looking at the finished bike I asked Hank what was the most challenging aspect of the build. “It’s what you don’t see that was the most difficult” said Hank. “We hid all of the wiring and hydraulics inside the frame and handle bars. I didn’t

use any hose clamps or zip ties”. And he’s right. Her sleek lines are virtually unmarred by any hint of wiring or plumbing.

Hazy Thoughts is a big, menacing looking bike. Yet despite her size she’s also very sleek and elegant. All in all, Hank estimates that he has approximately 400- 500 hours invested in the build over the course of the 6 years it took to bring this client’s dream bike to life. When I asked him to sum it all up, he said it was challenging, and often frustrating, but one of the most satisfying custom motorcycles he’s built to date. As we concluded our interview, Hank threw out a teaser, “just wait until you see what I’m doing next...” One can only imagine!