Pan Project – A build diary

**Remember to keep checking this post for progress**

Its 8am Tuesday here in Geelong Victoria Australia and I am patiently awaiting 6pm Monday in Baldwin NY USA, why? Well it’s a long story that’s about to get a whole lot longer.

The beginning-

In 2013 I finally admitted to being in love with vintage America, I don’t know what it is but it represented an era of freedom, art and creation that I really admire. My wife and I planned our honeymoon in 2014 and set off on the time of our lives.

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Picking up our 1965 Econoline from Rhode Island and setting off across the vast American landscape gave us time to take in everything that we loved about this country, there was a 20 foot container awaiting us in Los Angeles and I wasn’t about to let the chance of packing the van full of things I loved pass me by.


Each night as my wife slept I scoured eBay, Craigslist and Instagram for that two wheeled fantasy. My dream was to own a mid 1950’s Harley Davidson Panhead, original enough to get into the country and modified enough so that I could enjoy it right away.

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The search taught me a lot, I started to narrow down my wish list and I began to understand exactly what I wanted, what I wanted though was to be a needle in a haystack, an expensive one at that.

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The more refined my search the more difficult my selection began and it turned into something that wasn’t possible at all, I knew what I wanted and to be perfectly honest I couldn’t find it, I was looking for something that only I could create, I needed a distraction and it came the night before the Born Free show.

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That next day I scoured the grounds of the Born Free Show for a 1967 Harley Davidson Sportster, its owner advertising it just the night before on Instagram, I finally found it and stayed with the bike until its owner returned. I was the proud new owner of a 1967 XLCH Sportster modified in the way I desired and priced well enough to enjoy guilt free.

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That was 3 years ago, I have thoroughly enjoyed my 1967 Sportster and it has cemented the fact that this isn’t a passing phase in my life this is a true desire and passion. It’s a struggle to understand why, I ask myself constantly why I enjoy these old bikes so much but I just do. With 3 years passing my search for that mid 1950’s Panhead has never stopped, with each day passing by the recipe to my Panhead dreams has changed, each scenario has played out in my mind and each design idea has made my search that little bit harder.


Its now 5:30pm in New York and Daniel Popowich is on his way from Philadelphia to Baldwin to meet a stranger to pick up ¾ of a bike that I found on ebay. Sounds crazy right?

As I said earlier my search has never ended, in the past three years I havn’t found an opportunity to turn my hopes and dreams into reality until now.
I found a bike in Baldwin NY that fit my criteria exactly, all I needed was a motor and a frame that I can use to create what I want to create, the rest I can source either locally or create from scratch.

After finding the bike on eBay I started the search for someone decent enough to help me out, I emailed a few locals and neither could help me out, I emailed the seller and he wasn’t much help either, I let it go and resided to the fact that it was the one that got away.

Every now and then in life you have to admit that if its too difficult to create a situation then it may just be for the best, I was comforted in the fact that missing out on this was a positive thing, the comfort didn’t last long……


The very next day the bike was relisted and I thought I just needed to work harder to make the situation happen the way I wanted it to. I reached out on Instagram and was overwhelmed at the support I received, a long-time friend whom I had never met Daniel Popowich msgd me and said he could help. Daniel has been on a similar path to me on other sides of the globe, heavily involved with motorsport and also motorcycles he was the one I was looking for, a dependable smart and trustworthy person that is going in to bat for me.

So as I write this Daniel is on his way to the Nassau border near Brooklyn to meet a man who holds my hopes and dreams in the back of a pickup truck, all this effort for an engine in a frame that I have never seen or know very little about.

The Pan Plan:

My 1967 XLCH is a beautiful thing, it does almost everything well, the only downfall is the prolonged highway riding really takes it out of it, the high revs at 100kmh give it a limited lifespan, at 50 years old its in a mechanical happy place and I don’t want to disturb it.
The Sportsters big brother is a Big Twin built for cruising at 100kmh they are a powerful large capacity bike that still shares the simplicity of a bygone era. I learnt a lot working on 67 XLCH and with my apprenticeship done it’s now time to build my own.
The bike in question isn’t really a bike at all, it has three things going for it, 1 the price….. 2 the engine…… 3 the frame!

Living in Australia makes a few things difficult, none more than buying vintage American motorcycles. Over the past few years I have been flicking between a few different scenarios

• Should I buy a stock standard mid 50’s Panhead, keep the stock parts and then modify the bike into my dream bike? Seems like a lot of wasted parts and money with a lot of restrictions put on my artistic freedom by keeping it all genuine.

• Should I purchase a mid 50’s engine, reproduction frame castings and create a bike that may need a full mechanical rebuild in a matter of a few months riding? 67 years of unknown mechanical history is an expensive experiment.

• Should I buy a brand new reproduction Panhead engine, reproduction castings and then build a bike from scratch? Possibly the best way to go about it but that’s $15,000 and all I have is a lump of steel frame sections and a motor that are not really vintage at all..

So when I checked eBay and found an original frame with a near new Panhead engine sitting in it, wide glide front end, chrome oil tank, tins and a set of wheels for $5,000 US dollars I jumped on it.

That’s 15k of value for 1/3 of the price, I can’t confirm that it’s an original frame but if it is I have struck gold.

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Daniel just sent me through some photos, he has it all loaded up and ready to head back to Philly, I am that excited, Daniel said the previous owner had over $10,000 worth of receipts for the motor alone. I felt sick to my stomach this morning thinking I was in for the worst day of my life, turns out it’s all gone to plan and my new project is one step closer to being a reality, it’s a long way away but I feel like its closer than it’s ever been!

Its now the 11th of March, I have been trawling through information and parts to complete the bike, I have nearly 0 information on what exactly everything is so its proving difficult to organise anything. The thoughts of flying over and getting it running have been going through my head, it would be wasted time though as the parts would still need to be shipped from all over the country.


I stumbled across Dan Carr, Dan operates DC Choppers in Spicewood TX and is one of the most knowledgeable builders in the business. I found a phone number and decided to give him a call. I explained that I had bought a Panhead project in New York, its sitting in Philadelphia and I need a bunch of things for it. He was open to the idea of shipping it from Philadelphia to his shop and finishing the bike for me.

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He asked me to write a specific list and email it to him along with the address of the bike so he could organise shipping.

I wrote a specific list and I started to realize that I am doing the right thing, Dan is a smart man, he will get the bike fired and source all the parts I need, my plan is for it to leave his shop with all the parts I need minus the fabrication that I can complete once the bike is shipped home to me, this way I end up with the very specific parts I need, a complete bike that will pass the import permit process and a complete project that I can specifically finish off in my own style.

Its now the 13th of April and Dan just sent me an email explaining that the bike had made it to his shop. I was excited to finally get an educated opinion on my purchase, I have studied the 15 photos that I had of the bike and came to a few conclusions and I was hoping Dan could verify a few things for me. So I gave him a call. We chatted for a bit as he walked towards it, the first thing I needed his opinion on was the frame, I explained to him that the neck area looked like an early Knucklehead casting but it had me baffled why it had a Panhead tool box mount. He ran over the frame and said “Oh yea this is a standard Panhead frame, its really nice but looks like the neck has been changed at some stage to a Knucklehead neck” this validation makes the effort to finish the bike even more worthy, there is a lot of history here and I cant wait to see the bike live again.

We spoke for a bit about gearboxs, ignition, clutches carburetors and agreed on a plan. All Dan needed from me was a specific list of the parts I wanted and enough cash to order them, it couldn’t have worked any better as Dan was a dealer for all the brands of parts I needed, it cuts out so much unnecessary cost and not to mention postage time.

So Dans ordering the following

An S&S Super E Carb setup (same as I run on my two Sportsters) an MM74E Morris Magneto in brushed satin, a Revtech 4 speed Transmission with a flat alloy blasted finish, a Panhead kicker cover and a 1.5″ BDL belt drive setup and dry clutch.

So the plan is to get the Magneto fitted up, the carb on, the transmission fitted, the clutch, fresh oil in everything and then get it fired up and see how everything is.


Dan just sent me this picture of the bike in the workshop, he has everything ordered and on its way, I am way more excited about this project now and want to take it to another level than previously planned. While Dans gathering the parts needed to make it run I can plan the aesthetics and function of the bike.

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I had been thinking about the front end for a while, choppers to me need to be skinny and that is why I always longed for the Mullins Chaindrive Trees on my current Sportster, I chose Mullins solely because the guy is an all round mechanical artist (cars and bikes) that works hard at his craft, I like that and I look up to guys who have those values.

mullins chain drive from Norman Bonney on Vimeo.

You definitely need to follow Brandon on Instagram too, his wordsmith technique is second to none.

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But I want this bike to be different to my Sportster, I still want it to be skinny but I want to reflect the era that it originated in.

Meditation 4 Madmen | Jasin Phares and Harolds Iron Works from Meditation 4 Madmen on Vimeo.

Introducing Jasin Phares and his take on the Harley Springer fork. Jasin is another guy who is a mechanical artist who runs his own shop and stays true to those values I love. His take on the Springer fork is perfection, there is a 50mm reduction in width with the bottom tree cast in Ductile steel and the legs electric brazed, its a work of art.

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It would be the perfect fit for my project, original style, slimmed down to suit the new profile of my machine. So I sent Jasin an email and he is happy to accommodate my every need, he can construct the front end to be a complete bolt on, supply the axle to suit the star hub I am planning to run, build the bars, install the internal throttle and then get the entire thing chromed to complete one of the most amazing front ends. I am going to wait a few weeks and let Dan work his magic on the driveline, once its all running then I will work with Jasin and get this front end under way.


The more I think about this bike the more excited I am to get over there and ride it. Time will tell but all I can think about is getting my knees in the breeze and spending a few days rolling from Texas to the Californian countryside.

To be continued……………