View Full Version : Flying Monkey Build Thread

12-21-2009, 6:13 PM
I followed SuperCrouton's Angry Monkey build from another forum, and fell in love with the Cole Foster style of bike. I decided that my next build would be along the same lines. I loved the lines and the stance, so we got ahold of a 65 Tiger and got started. This build is going to take at least a couple months, hopefully having it done for springtime.

After looking through the local ads for a while, found this 1965 650 Tiger. The price was right. Didn't run after the owner put in high compression pistons. This is the spot that we found it; in a barn behind the guys house. Apparently he and his brother had done the work and got frustrated with it years ago and let it set.


We got it to the shop, cleaned it up and got it running. Ball valve was stuck, dumping oil everywhere. Other than that, it runs like a champ.


Stripped it down, trying to sell everything that isn't needed to fund the parts we need.


Stripped down the frame to the bare essentials. Still a little more left to go. Started mocking everything up.


I have a springer from the 80's that is waaaayy long right now. Still needing a 4-Under springer setup. Ordered front tire so we can mock up the wheel. Currently it sits with 3.5" of clearance, which seems pretty low to me, but it looks good.

12-23-2009, 9:49 AM
Looks good so far. Keep the pics coming!

12-24-2009, 4:10 AM
Got a little more done yesterday. Got the old bearing races out of the head, got a lot of the frame paint off, the front end set and marked to clearance for the steering stops, and started getting the frame set up for our cabling. Waiting on the correct gas tank, but set a spare OEM that I had setting around just for shits n giggles. Need to find a 21" front rim between 1.85" and 2.5" wide so I can get the tire on it and get my axle centerline height. Then we can get the numbers done for cutting the front end down and for the dimensions of the rockers. Wont be getting much more done til after the holiday now.




12-28-2009, 7:54 PM
Got the motor back in the frame for exhaust setup and to get the frame prepped for the hidden wiring. Also prepped the gas tank to build the internal oil tank. Still trying to find a 4-under front end. Argh...




12-29-2009, 11:09 PM
Got the separation plate built and the oil filler cap aligned and partially brazed on today, going to finish the cap tomorrow and get the separation plate installed tomorrow, possibly even get the tunnel back in the shell if possible.




01-10-2010, 2:27 AM
Haven't updated in a few days, been busy. Got the oil tank built inside the stock gas tank, then wasn't happy with the way that it was going to turn out, so decided to build my own tank and build an oil tank under the seat that followed the lines of the DB hardtail. Also started building some aluminum plates to cover the new rear motor mount brackets that would look better with the primary and transmission cases.






01-22-2010, 1:25 AM
Got the tunnel most of the way in, pie-cut the head end of the tank tonight, I only get a few hours at night to work on it, so it's not going nearly as fast as I want. Front end should be here any day (ordered it almost 2 weeks ago..). The tank is going to need lots and lots of filler.

Pie cutting the front of the tank, the left has been cut, the right has not.

After filling and semi-smoothing the front end. Any guesses on how many pinholes there are? Lol.

01-22-2010, 6:28 AM
Lookin' great, sorry you put all that work into the first tank, but the new one looks sweet!!!!

01-29-2010, 1:08 AM
Gas tank is finished up, brake line routing in the subrame and frame started tonight after getting the rear motor plates built. Doing tank mounts tomorrow night. The tank isn't 100%, but TONS of respect to the guys who bang these things out day after day. I now know why the TV guys make their tanks out of aluminum. Beating on steel is a complete PITA.





02-25-2010, 3:52 AM
Got a little more done in the last week, got the headlight hung, ended up getting the neck bearings from LowBrow, but they ended up sending the wrong upper bearing. They said they are sending another, just waiting now. Charlie is sending me a skinny front hoop w/o brakes and a 16" rear so I can mount up the Avons that came in. Got the oil tank design finalized and started on the main portion of it. Anyone have any idea what thread pitch I need for the triumph basket style filter inside the oil tank? Also, what diameter of tubing do I need to run my return line so I can get pressure to the rocker feed line?

Anyways.. got the seat pan built and mocked up with a beehive spring. Still unsure about how that's going to work. Got a 12V stator ready to replace the 6V that's in it so I have more options on headlight, taillight and coils. Got the rear motor mount nearly finished. The gas tank is completely sealed up and will be starting on bodywork tomorrow. The rear fender is getting close to needing struts made. Just need a couple extra hands around to help mock them up. And the bars and hand controls are in, but I need a tubing bender to get a little bend in them.



02-25-2010, 6:29 AM
looking good!!! Keep the pics coming, I love how this bike is coming together. I had a Cole Foster tank on my first bike...they give such great lines!

02-25-2010, 6:49 AM
This thing is really shaping up! Keep up the awesome work!

02-25-2010, 6:33 PM
I really loved the Cole Foster tanks, but we ended up building this one out of 20ga flat steel on the shot bag, english wheel and planishing hammer. I got it a little thinner than Cole's and with a little bit more cut at the front bottom edge. But the Cole Foster tanks are awesome!

03-04-2010, 9:31 PM
Got my front wheel in today from Charlie. The rear isn't a 16, but we're fixing it. I set the front up to check clearances... wow it's tall!

Also got the tank surfaced now that it holds fluids without leaking. Starting to look like a workable tank! Yippee!


Also got some bars to cut down; internal throttle and clutch setup from an old Harley. I'm hoping the internal clutch will work out. If not, I have a backup plan.


05-23-2010, 5:43 PM
It's been over 2 months since my last update... when customers have money, my stuff goes on the back burner. Got back on it this week for a couple hours though. Got the exhaust started, but now I need some 1.75" dia exhaust bends on a 2" radius (mandrel). I found some online with 2.5"CLR and ordered a couple U-bends. But still looking for the elusive 2"CLR>

STILL waiting on one of the two 16" dia rear hoops to show up that I've paid for so I can mock up the rear fender, get fender struts on it and finish the seat. Til I do that, no idea where the forward controls are going to go, and until I get that done, can't run my cables for brake or shift. So... pretty much everything but the exhaust and oil tank (got a surprise on that one) are waiting on me to either find a 16" hoop to put on my Triumph hub, or to have one of the two that I've paid for and never shown up actually show up. But, here's a semi-updated pic:


10-07-2010, 5:10 PM
Love the way this is coming along. Cant wait to see the progress. Nice job on the tank, trying one myself.

10-08-2010, 8:24 AM
how much of PIA is it to adjust valves with the tank covering the front rocker box?

11-30-2010, 12:04 AM
Got a little more done on the exhaust, got the rear fender in, but still waiting on a complete rear wheel to mock it up. The oil tank sides are at the CNC now, then it'll just be rear motor mount, and the little stuff that takes 90% of the time.


11-30-2010, 12:06 AM
Adjusting the front valves is going to require removing the tank. Not a huge deal, just 3 bolts. If I were hard up, the front covers are accessible, just not as easily as if the head was out in the open.

11-30-2010, 8:49 AM
Adjusting the front valves is going to require removing the tank. Not a huge deal, just 3 bolts.

you do realize that Triumph's require pretty frequent valve adjustment right? sounds like roadside fun.

11-30-2010, 3:26 PM
I'm not at all worried about it, if it were being built to ride cross country, I would have designed it differently. This is being built as a bar hopper toy. If the valves end up so far out that the bike can't make it home, pull two bolts, lift the front of the tank and adjust the valves on the side of the road. I've done parking lot surgeries that have had much more dismantling than that to make it home before. It's not like the entire head is submerged in the gas tank.. the gas tank sides look pretty low, but they are bowled underneath back to a stock tunnel.. I just pulled the inspection cap off of the right exhaust rocker and the adjustment nut is accessible. Not as easily accessible as a flat bottom tank, but again.. preventative maintenance with the tank lifted in the garage is easily completed.

11-30-2010, 3:56 PM
fuck ya i dig it !!

11-30-2010, 10:08 PM
love the slash cut pipes man, planning on doing something similar on my bike.

12-18-2010, 9:46 PM
Got the rear motor mount fab'd up today, and my machinist has the new bearing cups for my old front wheel done. All that's left now is the oil tank and rear fender then I need to figure out forward controls and wiring.

12-19-2010, 12:33 PM
Got the rear motor mount fab'd up today, and my machinist has the new bearing cups for my old front wheel done. All that's left now is the oil tank and rear fender then I need to figure out forward controls and wiring.

I was wondering about that rear motor mount? I was going to ask if you were going to change the square tubbing I've never ran one like that but heard they don't work very well. I fabbed mine out of round tubing. Here is a pic of mine please post a pic of your rear motor mount.

12-20-2010, 3:08 AM
I've got myne built with round tubing also. The square tubing was to get my distance and to ensure it was doing to clear the chain. My left motor plate still needs trimmed, but the rear motor mount bolts to the frame downpipe, then the side plates bolt to the stock motor rear plate locations. Chain clears, and it clears my oil tank.


12-20-2010, 1:10 PM
Starting to get the handlebars figured out. Using 1950's Harley internal cable bars. The clutch I'm still not 100% sure about, but the throttle side for sure. The angle is extreme on these things.




01-24-2011, 4:55 PM
Getting there now. Got the rear fender on, the exhaust crossover tubes going, rear motor mount finished, front wheel spaced, hard tail aligned and spot welded and bars finished up. The internal clutch line is ran, the throttle will need a custom cable built. Starting on footpegs and rear brake setup this week.


01-24-2011, 7:46 PM
Seat tooling started today. I'm stoked.

01-25-2011, 8:23 AM
that monkey looks angry.

01-26-2011, 1:17 AM
Got the sprocket spaced today, got the seat from my leather man, and got the powder coating set up. Final lengths of correct diameter stainless exhaust pieces ordered, just waiting on the oil tank parts to show up, then we'll ALMOST be ready to tear it apart for paint.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs765.ash1/165695_498761364235_689609235_5848249_5318800_n.jp g

01-26-2011, 1:49 AM
sexy ride bro its going to be beautiful when your done nice work

02-04-2011, 6:27 PM
Radiused fins. This piece cost me more than buying the original bike. Lol.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs786.ash1/167673_10150090570789236_689609235_5914119_8177952 _n.jpg

02-06-2011, 2:15 AM
This looks great :D

02-08-2011, 2:13 PM
Photographer came up last night and shot some pics... working on footpeg hangers and getting the last of the exhaust done, then stripping her down for final welding and smoothing the frame.



02-08-2011, 4:54 PM

02-10-2011, 3:55 PM
Dude, I really like the seat :eek: f'kn awesome man.

02-12-2011, 7:58 PM
Finished oil tank sides showed up today. Killer! Got ahold of Dan about my rear tire clearance issues... apparently a 150 rear tire will NOT work, have to go to the 130, which doesn't bother me in the least. Got it on order, just gotta take my oil tank and get it welded up (I dont trust my AL welding as only get one shot at this), then it's wiring and brakes and then off to paint.

02-16-2011, 12:10 AM
Got the oil tank welded up today, just need the feed and return fittings (and a vent). Also got the exhaust re-welded (the upper pipe pulled on me from inadequate prep work the first go around), and the oil tank mounting brackets built. The lines are close, but are spot on after the rubber bushings are there. Got the tank in final primer, and started in on cleaning up some of the spot welds that we had holding little stuff on (like seat spring perches, rear fender brackets, etc). Will tear back down tomorrow night and start finish welding everything.






02-16-2011, 12:12 AM
On a side note, the oil tank holds 3.5+ Qts of water (and it doesn't leak! Wowsers!). I was shooting for 2 to 2.5, I'm super happy with the volume this thing has!



02-17-2011, 1:05 AM
Got the front wheel apart and got the spokes and hub in flat black. Rear wheel this weekend.


02-17-2011, 3:13 AM
Also got some bars to cut down; internal throttle and clutch setup from an old Harley. I'm hoping the internal clutch will work out. If not, I have a backup plan.


First of. Looks great man!! Second.. How does this internal clutch work? Like an internal throttle?

02-17-2011, 11:47 AM
Yeah, just reversed worm drive on a couple bearings. Still unsure if it is actually going to have enough pull to work on a daily basis, but it looks like it'll work right.

02-19-2011, 5:00 PM
Coming along great! Keep up the good work!

02-22-2011, 1:53 PM
Tail light came in today. Got the rear tire swapped over, getting the front wheel in black to test out some new paints. Powdercoating was just too damned expensive.

02-24-2011, 4:38 PM
Looks great man, I'm sure Dan will be flattered!
The oil tank looks great- nice idea. One minor criticism, and I hate to say it, but I think it might have looked better if the spacing of the fins on the oil tank matched the fin spacing on the head. Either way it's tits, but for next time...

Keep up the good work-

02-25-2011, 10:55 AM
Thanks. The fins on the oil tank 100% match the fins on the head. Width, spacing, radiused end. That's what took so long was getting everything to match up with the head. The head on my bike needs cleaned (hopefully soon) so maybe it's an optical illusion, but holding the oil tank sides up to the head fins,they line up 100%.

02-27-2011, 8:13 PM
Oh right on! That's cool- I think it was just perspective screwing me up... I'll bet it looks tits in person.

03-01-2011, 11:51 PM
Front wheel is done, rear wheel is giving me a headache. The Harley Hoop on the 'Umph hub creates a problem with spoke alignment. Took a million pictures, but these damned spokes just dont want to go back in their home (insert Happy Gilmore "Are you too GOOD for your HOME?!" here). Anyways. Single 6v Dual fire coil on it's way from Canada, then figure out what all will fit under the gas tank, get the rear motor mount finished up and it's off to powdercoat. :clap for you:

03-02-2011, 12:22 AM
Nice job! I really like the bike.

03-07-2011, 10:58 PM
Both wheels done, exhaust hangers done, chain is on it, just need to get the kickstand finished up, pegs, then rear brake setup and the cables.




03-08-2011, 10:11 AM
Looks great!!!

06-12-2011, 10:52 PM
Got the next to final assembly done now. I dont really remember what all I've done since my last update, but right now all I'm waiting on is misc small stuff: rear brake linkage, clutch perch, cables, and getting the wiring harness built. Frame is done, front end is done, footpegs are done. As soon as I can test ride it, I'll figure out what color to paint it, then get it on the road.

06-13-2011, 9:29 AM
Looks very nice... great build.

07-18-2011, 11:11 PM
Getting closer. Brakes, electronics, and rear motor mount left for hard parts. About 2 dozen little things and polishing..

08-05-2011, 1:37 AM
Got the Monkey's wiring harness buttoned up while I was cooling down. Puts out a solid 12V when cranking it over by hand (awesome!!). Headlight works, taillight still needs a brake switch after I get the brake cable ran. Oh yeah... N&P finally got the last parts I needed for the brake finished up. Picking them up in the AM. Got the new clutch cable installed and working (*YAY!!*). Only things left are: -Hook up throttle cable, -Install Coil bracket and coil, -Tap petcock holes and get petcocks installed with new fuel lines, -Weld up rear motor mount and get it painted, -Paint seat pan, -Install chain, -Build rear brake assy and get wiring hooked up to brake switch. Then it'll be ready for it's shakedown run (hopefully next Wed/Thurs). After it's shakedown run it'll get torn back apart for some misc polishing, new clutches, get the handllebars prepped for rechrome, new headlight mount bracket, wheel bearings, rear brake pads (oh yeah.. can't take it out for shakedown til I find some brake pads... lol) and to get the peg mounts finished up. I was very surprised that the points were still working after sitting sealed up for 3 years. Timing is spot on, valve train seems to be in good shape, and the oil pump is pushing pretty well. Still need to figure out some new oil lines from the tank to the motor (and remember which one on the motor is feed and which is return... I ALWAYS forget which is which). The lower exhaust needs to come off and get final polishing before installing the new roll of exhaust wrap on it and get the forward clamps finished up.

It's come a ways. Hasn't been quick, but the light is visible at the end of the tunnel.

08-05-2011, 8:36 AM
its beautiful man!! simple sweet lines. a good mix of old and new school. oh to have the skills alot of you guys have :D

08-05-2011, 9:11 PM
Well played!

08-10-2011, 2:26 PM
Got the coil mount built and installed, oil lines ran and brake setup started last night. As far as I can tell it *SHOULD* start.. going to find out tonight. First time in almost 3 years.

08-11-2011, 12:42 AM
Everything seems to be in working order. Starts (sometimes first kick, but by the 3rd every time). Had an oil feed problem (feed fitting was too small, not enough oil), but got that resolved. Lights all work, cables are ran. everything seems in working order so far. Now to get the brake to work.

08-11-2011, 1:20 AM
Also got some bars to cut down; internal throttle and clutch setup from an old Harley. I'm hoping the internal clutch will work out. If not, I have a backup plan.


That's pretty sweet.

08-16-2011, 10:58 PM
Almost there. 90% done with the brake, still need to paint the seat pan and get the oil lines buttoned up to where they quit leaking. But really really close.

08-17-2011, 5:03 AM
good luck turning with those pegs...

paint looks nice.

08-24-2011, 1:13 AM
Turns just fine. Definitely not a knee dragger, but does just fine so far. :)

08-28-2012, 11:17 PM
Where did you find you front end? I want this same springer.

08-29-2012, 11:29 AM
Nice build, dig the bike.

08-30-2012, 5:07 AM
Nice build , It answered some questions I had about mine.. Did I read right ? You ran you're rear brake line through the Frame ??? Hows that working out ??

08-30-2012, 5:17 AM
Lobe the bike!! Looks super light.

09-02-2012, 9:33 PM
..Looks good , doing a fine job ,

09-02-2012, 9:35 PM
I shouldn't get on this sight when I've been drinking...:cheersmate:

09-08-2012, 3:58 AM

09-15-2012, 9:34 AM
I changed the color , Purple just wasn't doing it ... " Grashopr " - I have a set of bars like yours. and I was thinking about cleaning the front end up like you did.. Can you PM me and tell me what I'll need to run the Throttle cable through the bars.. .Thanks man...
BTW- That's one of the Best looking Bikes I have ever seen.. Harley , Triumph or any Bike ..... I LOVE it...

09-15-2012, 10:51 AM
Love it, cool bike!

09-27-2012, 7:00 PM
whats up phil, bike looks better every time i look at it. and whoever did the body work on that tank has some skills. haha. hit me up and we can go for a ride, piston swap should be done by sunday

10-01-2012, 9:31 AM
Is that a DNA Front End ??

10-12-2012, 2:34 AM
Where did you find you front end? I want this same springer.

Don't !!

Apart from that, nice work on the bike, especially like the oil tank.

10-12-2012, 2:35 AM
Is that a DNA Front End ??

If it ain't a DNA, someone copied a DNA... :rolleyes:

10-12-2012, 6:02 AM
If it ain't a DNA, someone copied a DNA... :rolleyes:

It wouldn't be the first time someone put there name on a DNA..

01-12-2013, 11:56 AM
Sorry, it's been a while since I've checked this thread..

The bars are a set of 50's Harley bars that were welded directly to the DNA (yes, it's a POS chineese springer front end, and it works and looks terrific. $$ was the deciding factor when I purchased the front end) upper clamp. The Harley bars were selected for the internal throttle and clutch worm drive. However, I just dont have the arm strength to run the clutch... it's just too difficult to hold for long periods of time.

Yes Trevor.. whoever did the bodywork on that tank IS a madman! :killerjob:

And thank you guys for the accolades. Rode the bike all summer, and it's a ball! Turns heads everywhere and I just love it. Want to build another one! :)

01-12-2013, 11:58 AM
Yes, I ran the rear brake line through the frame.. works pretty well! Teflon lined bicycle cable sheath routed up the rear tube from under the bike, turns and runs into the rear subframe, then out of the upper subframe tube and straight to a holder and to a modified brake arm. No safety backup, but it stops. :/