There’s this funky little tool that looks like a robot’s hypodermic that just pops the wiring out of the stock molex connectors. This tool is NOT included in the kit – and considering the handlebar wiring goes through the top triple tree on most bikes, you’re gonna need this tool. You can probably get one at your local Harley dealer, but the one I have in my toolbox came from Radio Shack and cost about five bucks. Don’t be a schmuck and cut the wires in your haste, you’ll regret it later when your electrical-taped monstrosity is spitting sparks and shorting out 8 miles outside of Lusk, Wyoming. This is one area where it pays to take your time and do it right. Ok, true story. I was buying a rolling frame off a guy once and I figured I could save some time by reusing the old wiring harness. I told the guy tearing the bike apart to “mark the wires” so I would know what wire went where. Several days later I received the frame with the wiring harness still intact and lots of little tape tabs on the wiring. The blue wires had a tape tab labeled “blue”, the red wires had a tape tab marked “red”, the yellow wires…well, you get the picture. I highly recommend you make a paper diagram and mark the wires 1, 2, 3, etc. and then put the numbers on your diagram. You think you’ll remember where the wires go, but you won’t and it’ll really louse up your project later. Now that we’ve got the handlebar connectors off, we can thread them through the top triple tree. Lay a shop blanket across the top of the frame, unbolt the bars and lay them back where the tank used to be. Loosen the top of the tubes with a really big wrench. At this point, take a moment to reflect upon what the remains of your front end looks like – because it’s about to change radically. Feed the troops some pizza and salad and beer. We’re trying to be healthy in our advancing years, but not that damn healthy. In fact, go out and smoke a cigarette or a cigar at this point. If anybody bitches, just show them this – it’s part of the instructions. Once the tube tops are off, remove the top triple tree. This is Scooter Trash pulling the trees off the bike. Yeah, he’s sweaty and pretty damn greasy at this point. The truth of the matter is, if you want to stay particularly clean – pick another hobby than chopper building. Everything always looks so nice and sanitary on those TV shows, and you know, maybe it’s like that because nobody ever actually rides those billet trailer queens except for the “money shot” at the end of the show. The truth is, if you ride a bike a lot, it (and you) will get dirty – but I’ve been told by many women that the aroma of gas, harley oil and human sweat is finer than any cologne they’ve ever put in a bottle. Oh, in case you’re wondering – this is what a real biker looks like, not “Mikey”. Next>

Badass Bolt-On Chopper: The ONE DAY Chopper Build Continued... The question has been around for a long time, and there are many different answers – but the one thing we can ALL agree on when asked the standard “What is a chopper?” question is that the damn things have a front wheel that sticks out farther than the manufacturer decided was safe or practical. The “chopper” name – just for the sake of good record keeping, comes from the frame being cut or “chopped” to achieve a different degree of rake on the front end – generally allowing you to make the thing really long. Nothing terribly philosophical or techie – you cut the frame, add longer fork tubes and, brother, you got a chopper. Next>