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The Beginning – More Than Just a Project
The rebuild of this ’77 Harley-Davidson Ironhead was far more than just a conversion—it was a real adventure.
What began as a simple task—pulling an old motorcycle out of storage—quickly turned into one of the most exciting projects ever.
There it stood in the warehouse: a heavily weathered Sporty with a coffin tank, drag pipes, forward-mounted footpegs, and an extended fork.
A half-finished chopper conversion from days long past—as if someone had started it years ago and simply never finished building it.
That was exactly where the opportunity lay.
And that was exactly what would give rise to something completely new.
The beginning: an old chopper, ready for a new chapter.
Three apprentices, one engine, and plenty of motivation—the launch of Iron Rookie.
This is where the vision begins—the first idea taking shape.
The first prototypes of the Iron Rookie are starting to take shape.
The Idea – Freedom Meets Vision
The assignment was clear: a complete rebuild, with no set guidelines.
Maximum creative freedom for the apprentices.
Three apprentices took on this task: Moritz in his first year of training, Ronan in his second year, and Justin in his third year. Together, they rose to the challenge of creating something completely new from the old bike.
The direction quickly became clear: no chopper, no standard bike—but a flat-track bike.
Raw, sporty, stripped down to the essentials.
A bike that not only looks good but rides just as well.
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Back to square one – completely disassembled
To even begin to understand what we were dealing with, the Ironhead was completely disassembled. Down to the very last screw. This wasn’t just a matter of tightening screws—this was real work. Hard work.
Every component was laid out on the table, inspected, evaluated, and scrutinized. What can stay? What needs to be replaced? What can be improved? For the guys, this meant one thing above all else: getting their hands really dirty and diving deep into the mechanics. Because it quickly became clear: Taking it apart is one thing—but putting it all back together so that it works perfectly in the end is the real challenge.
Technology Reimagined
The engine has been completely overhauled—without compromise.
New pistons, new bearings, new gaskets. Everything was inspected, measured, and meticulously reassembled.
The transmission was also inspected and overhauled.
The goal was not only to build a visually striking bike, but a technically reliable machine.
A bike built not just for the stage—but for real-world use.
This laid the foundation upon which everything else could be built.
That was the reality—completely worn out and long overdue.
The guys: Lucas providing support and Andreas keeping an eye on the big picture.
A look inside – every detail has been checked here.
Customization – truly handcrafted
Many components were crafted entirely by hand.
The rear end was developed and built in-house.
The exhaust system was completely redesigned and, in collaboration with the welding department, realized as a striking under-seat configuration.
The wheels were also re-spoked and precisely trued.
A new, streamlined wiring harness was created—reduced to only what a true flat tracker needs.
Instead of a classic headlight, the Ironhead now features a race number plate that consistently underscores its racing character.
Every detail serves a purpose.
And every part tells the story of how much work and thought went into this bike.
Racing DNA down to the last detail – with a convenient quick-release mechanism.
Development of an adjustable swing arm mount for various setups.
The under-seat exhaust was installed, but getting there was anything but easy.
The rear fender was custom-built in several sections around the exhaust.
More than just technology
This project was not only technically challenging, but also personally meaningful. It was a sign of trust that, as an apprentice, I was given the responsibility to build a bike like this on my own.
With the support of experienced colleagues—often working late into the night—we didn’t just build a motorcycle; we gained real-world experience.
It wasn’t just about tinkering with the bike.
It was about making decisions, finding solutions, and working together as a team.
On Track – From the Gravel Pit to the Snow Race
Once it was finished, the moment everyone had been waiting for arrived:
The Iron Rookie had to show what it was really capable of.
For the first photo shoot, we headed to the gravel pit—exactly where a bike like this belongs.
Dust, loose surfaces, and long drifts made for the perfect playground. For some of the guys, it was their first time on terrain like this, but that was exactly what made it so exciting. The Rookie handled cleanly, the rear wheel spun willingly, and the bike immediately proved that it doesn’t just look good—it works, too.
But that was far from the end of it.
Shortly thereafter, the Iron Rookie headed to Willingen for the Snowrace.
A completely different challenge: snow, steep inclines, and extreme conditions.
Justin hopped on the bike and rode the Rookie up the mountain—and did so with an impressive performance. In the carburetor class, it posted one of the fastest times.
From the gravel pit to the snow—the Iron Rookie has shown what it was built for.
After all that work: finally ready to be driven.
For your hard work, dedication, and passion—helmets with the perfect design.
Done. And proud.
From the gravel pit to the snow – Justin and the Rookie in Willingen.
Bike & Details
Riding
Flat Track Feeling
