Battle for the Crown!
These rules are just the way we like it.
This was the birth of the Emperor, our battle bike based on a 1995 Evo-Sportster. The year of construction is also the birth year of Kim, the daughter of the company founder Andreas Bergerforth.
The bike was mainly built from scratch. The many handmade parts with countless details make this bike a unique, absolute top class Sportster.
Highlights such as the fork, handlebars, fuel tank, oil tank, seat, sissybar, fenders, struts, exhaust and shifter, as well as the unique swingarm and the completely revised engine with an automatic clutch. All truly unique parts that have not been built like this before.
- Front Wheel – HD Ironhead 2.15×21
- Front Tire – Avon Speedmaster 3.00×21
- Rear Wheel – TTS 4×19
- Rear Tire – Shinko 4.00×19
- Fender/ Struts – Thunderbike
- Sissybar – Thunderbike
- Brake Caliper – HD Ironhead
- Brake Disc – Thunderbike
- Fork – Narrow Glide Ironhead
- Tripe Tree – Thunderbike
- Turn Signals – Thunderbike
- Headlight – Thunderbike
- Speedometer – Motogadget
- Speedo Bracket – Thunderbike
- Handlebar – Thunderbike
- Master Brake Cylinder – Kustom Tech
- Internal Grip Set- Müller
- Automatic Clutch – Rekluse
- Power Filter – Thunderbike
- Grips – Thunderbike
- Foot Controls – Thunderbike
- Fuel Tank – Thunderbike
- License Plate Bracket – Thunderbike
- Brake Drum / Wheel Hub – HD Ironhead
- Schwingarm – Thunderbike
- Shock Cover – Thunderbike
- Engine Cover- H-D Chrome Kit
- Primary Cover – H-D Chrome Kit
- Timer Cover – HD Life to Ride
- Clutch Cover – HD Life to Ride
- Rocker Box Kit – H-D Chrome Kit
- Exhaust – Drag Pipes
- Seat – Spirit Leather
- Engraving – Carsten Estermann
- Painting – Chiko´s Pinstriping
Stripping & Inventory
The swingarm is one of our favorite parts for very special bike projects.
The design was created by us in a highly contemporary method on the computer. The realization, on the opposite, was created in the old blacksmith’s method. As you can see in the Making Of, it all started with a simple steel tube, which was bent by Jörg and Reiner with lots of fire, smoke, and pure „Craftsmanship“.
Two folded parts and two machined parts form the connecting part to the bearing points on the frame, so the front section of the swing arm is finished. The rear part of the swingarm is much more complicated, more than 20 individual parts that are welded together are necessary to bring this sophisticated form together with corresponding function. So the brake arm support, chain adjuster, lower shock mounts and license plate bracket are not simply bolt on, they blend in perfectly into the design of the swingarm.
Fender, Struts & Sissybar
The Sissybar fits seamlessly into the process. The basic material used was also an old strut that we designed some the ago for the Boss Hoss bike Hoss Power. But even here it was only a template for a new design! We also came up with a nice solution for the rear light and the indicators.
Air Cleaner and Engraving
To turn our King of Kings competition bike into a show stepper, the bike needs, besides all technically complex suspension solutions, an immediately recognizable value!
For this purpose, we have set some accents in golden brass. We milled all parts from the full material. We don’t want to give away all the parts we made, but we made some exclusive parts like air filter cover and exhaust end caps. But that was not enough for us! To get more details of the bike, we got the engraver Carsten Estermann on board. Carsten engraved some of the parts by hand with a dremel.
We were impressed not only by his creativity in choosing the motifs, but also by the extremely consistent depth of the engravings that he removed from the metal.
The manual gear lever is a very special unique piece and is also a technical high-end solution.
The development begins with a seating test, because the lever should be easy to reach during the ride! Afterwards a rough sketch is made on cardboard, which is then provided with lengths and widths in further steps. It is important that the two steps of the primary are taken into account, so that the lever can later be moved close to the bike. With this information we went to our CAD designer Andre. From his sketches and in close cooperation with the guys in our custom workshop he makes a three-dimensional drawing. By the way, the lever was designed in exactly the same design as the lever of the foot brake. Once the drawing is finished it’s translated into a program. This process alone takes 8 working hours! This work step is so complex because the milling machine does an incredible job with 5 axles and therefore all swivel ranges and interfering contours of the machine have to be calculated. The lever is machined out of a solid block of billet aluminium and later polished to a high gloss finish in our in-house polishing department. For complete refinement a brass knob is turned, which is also refined by engraver Carsten Estermann.
We are proud of this splendid piece!
Because the roadworthiness is a necessary condition for the King of King competition, we couldn’t do without speedometer and indicators. After a long time of testing we found a suitable place for the necessary components. For speedometer and indicator lights Andre designed us a nice bracket – of course matching the headlight design! Have you already discovered the turn signals? Like two little snakes they wrap around the fork pipes! It is one of the smallest but still one of the most brilliant specials.
Another highlight of our King of Kings bike is certainly the oil tank. This is completely handmade and has not yet been built by us!
But those who have followed the steps so far already know that this does not even just happen and of course it comes along with unexpected turns. The rough shape of the oil tank starts with a cardboard template which mechanic Reiner, an icon in our custom workshop, forms by hand. The shape of the oil tank is very important to give our bike a slim look and to guarantee a good transition between the rear and the front end of the bike. To achieve this, it must sit centrally in the frame and be positioned in good relation to the adjacent rear fender and frame tube. The cardboard template must now be transferred to 1.5mm sheet of steel, which is very challenging, because cardboard can be bent in itself and therefore the template can only serve as a rough template. Our welder and specialist for the tricky tasks, Jörg, has left the sheets 1cm longer at the ends to shorten them later to the right size. In spite of this safety precaution, at least one tank usually goes “six feet under“.
To give the tank more optical depth, a 6mm hydraulic pipe is folded over at the edges and shaped into a fin. It is important that the fin is tinned and not filled, because the strong vibrations of the V2 engine can later lead to cracks in the filler and paint. Because of this, the tank is also mounted on rubber bearings in the frame. In order to be able to execute its function later on, the connections for outlet, return and ventilation are welded in.
„The perfect fit“
We had determined the style for the seat of the King of King Bike relatively early, because if you are serious about a chopper, there is no way around a King & Queen seat.
What he brought over to us 3 weeks later left many a jaw dropped. A bench seat that fits like a glove. He choses a water buffalo antique finish for the surface, which harmonize perfectly with the paint of the bike. The stitching is decorated with brass rivets and the Thunderbike logo proudly emblazoned on the back.
In the style of the 70s, Jimi from Spirit Leather has thus perfectly implemented this theme. With the seat he created the perfect transition between tank, fender and sissy bar.
Exhaust and Endcaps
In the end they decided to use drag pipes, which now have little to do with their original form.
When choosing the manifold, we made sure that they do not compete with the footrest and the foot brake lever.
An important point for the later line of the bike is the rear angle where the pipes rise. Since no connecting piece with the desired angle was available, we simply made it by hand ourselves.
In addition, the pipes have been given a slight recess to make them fit even more smoothly around the rear shock absorbers and thus bring the exhaust pipes closer to the frame.
Battle of the Kings Finale 2017
As part of the Hamburger Motorcycle Days, the final of the Harley-Davidson Battle of the Kings 2017 competition took place. We made it again among the best!View Details
Battle of the Kings Finale 2016
We had already won the German Battle of the Kings final and thus got a ticket for the EU final in Biarritz on the "Wheels & Wave". Now it was all about - the overall winner of the EU-wide customizing competition was announced in San Pedro, Spain.View Details
Customparts, Dealer Support
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