Custom Harley Davidson Dyna build

Field: Motorcycle customization / Mechanics / CNC and lathe fabrication

Period: 2013 (1 year in my spare time)

Client: Personal project — skills showcase

Model: Harley Davidson Dyna 1996

Background

In 2013, I turned my Harley Davidson Dyna 1996 into a skills showcase — a personal project demonstrating the full range of my abilities in mechanics, CNC/lathe fabrication and high-end customization.

Objective:

• Transform a classic chrome cruiser into a modern race bobber
• Show my skills: 3-axis CNC machining, turning, TIG welding, electronics, mechanics
• Create a one-of-a-kind bike that serves as a technical demonstrator

Mission: A complete transformation — only the engine, the main frame and the wheels remain original. Everything else: redone, replaced or made to measure.

Duration: 1 year in my spare time (alongside the workshop)

Problem

Technical challenge:

• 60mm inverted fork: adapting it to the Dyna frame (not designed for this type of fork)
• Dual 6-piston Beringer Aerotec front brakes: race calipers, custom mounts
• Wide triple tree: requires turning brake disc spacers (to adapt the dimensions)
• 3-axis CNC-milled engine covers: custom finishes
• Wiring inside the handlebars: all the wires run inside (drilled handlebars)
• Complete electrical overhaul: Motogadget CDI, RFID ignition, key switch removed

Aesthetic challenge:

• Cruiser → race bobber transformation: a taut, minimalist line
• Short rear fender
• Solo race seat
• Sunset orange paint job (fire gradient)
• Professional finish (no visible cables)

Solution

Phase 1: Designing the build

Analysing the original bike:

• Dyna 1996: standard fork, basic brakes, conventional electrics
• Kept: engine, frame, wheels
• Replaced: EVERYTHING else

Vision for the build:

• Race bobber style: an aggressive, minimalist line
• 60mm inverted fork (sport-bike type)
• Race braking: dual front discs, 6-piston Beringer calipers
• Motogadget electronics: modern CDI, RFID ignition

Phase 2: Making the custom parts (CNC/lathe)

Custom-machined parts:

3-axis CNC milling:

• Engine covers: CNC milling for custom finishes
• Brake brackets: mounting the 6-piston Beringer Aerotec calipers
• Inverted fork mounts: adapting to the Dyna frame (non-standard)
• Miscellaneous mounts: brackets for electronics and sensors

Turning:

• Wide triple tree: requires turning brake disc spacers
  
• Handlebar end caps: drilled to route the cables internally
• Bushings: adapting to the 60mm fork diameter

TIG welding:

• Frame mounts
• Custom brackets

Phase 3: Mechanical assembly

Suspension & braking:

• Installing the 60mm inverted fork
• Adapting it to the frame (custom CNC mounts)
• Custom-turned brake spacer (wide caliper)
• Fitting the dual 6-piston Beringer Aerotec front brakes
• Aviation-grade brake lines (performance braking)

Motogadget electronics:

• Motogadget CDI: replaces the original CDI
• RFID ignition: key switch removed (keyless start with an RFID chip)
• Digital speedometer: modern display
• Complete rewiring: all the wires run through the handlebars (invisible)
• Drilled handlebars: internal electrical cables (no external cables visible)

Line & aesthetics:

• Short rear fender (bobber)
• Solo race seat
• Original tank kept
• Matte black custom exhausts

Phase 4: Paint & finishing

Custom paint job:

• Sunset orange: fire gradient (orange → yellow)
• Applied to the tank and rear fender
• Professional gloss finish

Finishing:

• Chrome removed → matte black (fork, engine)
• 3-axis CNC-milled engine covers (visible detailing)
• Minimalist finish (no visible cables)
• A coherent race look

Results

Deliverable:

• Harley Davidson Dyna 1996 transformed into a modern race bobber
• Personal project: skills showcase
• Duration: 1 year in my spare time
• 60mm inverted fork + dual 6-piston Beringer front brakes
• Wide triple tree: turned brake disc spacers
  
• 3-axis CNC-milled engine covers
• Complete Motogadget electronics (CDI, RFID, invisible wiring)
• Custom sunset orange paint job
• Only parts kept: engine, main frame, wheels
• Everything else: replaced, fabricated, custom-machined

Skills demonstrated:

• 3-axis CNC milling: engine covers, brake brackets, mounts
• Precision turning: disc spacers, handlebar end caps, bushings
• TIG welding: frame mounts, brackets
• Advanced motorcycle mechanics: inverted fork adaptation, race brakes
• Electronics: Motogadget, RFID, invisible wiring
• Engineering & design: complete cruiser → race bobber transformation

Impact:

• Technical showcase: a demonstrator of multi-disciplinary skills
• Personal project: no client constraints, complete freedom
• 1-year duration: a spare-time build alongside the workshop
• Professional result: commercial-grade finish

This project demonstrates:

• The ability to radically transform a motorcycle (cruiser → race)
• Command of 3-axis CNC: milling engine covers and brackets
• Command of turning:  brake disc spacers
• Advanced electronics: Motogadget, RFID, invisible wiring
• Precision mechanics: inverted fork adaptation, race brakes
• Aesthetic vision: a coherent, polished race bobber
• End-to-end project: design, fabrication, assembly, finishing

Photos/Visuals

Tags: lab, motorcycle customization, Harley Davidson, Dyna, bobber, race, inverted fork, Beringer, Motogadget, 3-axis CNC, turning, showcase, 2013