For the better part of two years now, Jay and I have been discussing the best way to approach updating our frame table to significantly improve its accuracy, range of capabilities and reduce job set up time, calibration needs, etc. Basically, we were trying to decide what the best approach for US was to build a killer frame table. Something that would allow us to not only do frame modifications like hard-tails, but build complete one-off frames, fix bent or broken frames with accuracy and reliability, and who knows what else.;

Welcome to the latest How-To installment from Jay Roche at Special '79/Barnstorm Cycles. This tech tip is related to their Sportster project, but can be used on anything you might be working with that requires something built out of aluminum sheet.

My son is about to turn 18 and has a regular driver's license and expressed interest in getting his MC endorsement. In California, if a rider is under 21 years of age they are required to take a motorcycle safety course and the course eliminates the need to take a riding test at the DMV. Over 21 it is optional. Since my boy was signing up for one, there was no way I was gonna let him do it alone. I've had more friends go down than Ellen this year, so a safety course seemed like something that couldn't hurt and there was an off chance that I'd actually learn something.

Our Sportster project is sitting here all pretty with the stock rear section still intact. Since we're doing a couple hardtail sections on some Evo Sportsters, we decided to fab up a motor dummy fixture that will maintain the stock motor mount locations while we cut off the rear section to make room for the new Led Sled hardtail going in its place. On most frame jobs of this nature, the motor itself would be used as a fixture, but our motor is being prepped for the 1200 kit while we do the hardtail.

In Massachussetts I've been hassled a couple times for not running turn signals, so trying to figure out how to run them without standing out too much seems to be a common theme with me. Here's a simple way to tuck them in cleanly and easily, even if they still aren't totally legal. I illustrated this how-to using a 39mm aluminum lower tree, but these tips can be reworked for a variety of different setups.

Ok people, this is the beginning of documenting the Barnstorm Cycles/SPCL '79 transformation of a lowly, stock, ratty 1986 Sportster 883 into a lean, hardtailed 1200cc custom that you can be proud to ride, even while you're friends are watching. Over the next handful of articles, we'll be going over the complete processes involved in the rebirth of this bike; sorting any mechanical issues, fabrication, and aesthetic included. The idea for these articles will be to lay out the steps we follow to put together a budget build from start to finish using evo sporty powerplant.

Today the Worecester Wizard shows us how to properly mount a flat-bottom Frisco-style Sportster gas tank using rubber bushings. The cool thing about Metal Shop features with Jay is that the old pros can still learn something by watching someone else's work and noobs can get a serious jump start with a little digital mentoring. Read on, and then go out in the garage and melt some shit together.

Making a functional and bulletproof motorcycle part out of a raw chunk of metal on a lathe is a rewarding experience for the self-sufficient motorcyclist with such a machine at his disposal. In this installment of Metal Shop, Jay from Special '79 Fabrication/Barnstorm Cycles uses a taillight project to illustrate some simple but effective machining methods.

With winter project season around the corner, fall feels like a great time to resurrect some of the best how-to's on the old 33. These tips were submitted by CC readers to help their fellow grease monkeys get the most out of the garage shop experience.

So, you want to be a daredevil and shave the fender and caliper mounts off your fork lowers? Cool, just make sure your rear brakes are tuned up nicely and give yourself plenty of braking distance. I'm certainly not opposed to running front brakes, but it sure looks nice and clean when your front legs are shaved and your bars have minimal controls on 'em. The following little video is how we go about this process in the Barnstorm Cycles/SPCL'79 shop. Enjoy!