A Testament to DIY: 1960 XLCH Chopper Build

Chopper Dreams

Jared Smith had a vision but not enough skills to make it happen — so he taught himself. As his first custom bike project, the bar was set high with a non-running 1960 Harley-Davidson XLCH. Facing a steep learning curve, Smith turned to YouTube for some much-needed schooling. One year later, with a flux-core welder in hand, he realized his chopper dream.

Photos courtesy of Pipeburn.

Vintage Look

With a little high-tech help, this low-tech build is a reminder that determination gets results. The XLCH is more than just the sum of its parts — the attention detail is obvious. Smith reflected on the look, “I was going for an old but loved look... using vintage components where I could that had not been refurbished, everything else I wanted to make by hand.” 

Photos courtesy of Pipeburn.

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Top and Bottom

Smith immediately pulled the XLCH apart once it was in his garage. In the 'keep' pile were the engine cases, frame, and seats. The motor was in dire shape and needed new cylinders, pistons and a set of heads. Hannan’s Machine Shop in Hayward, California was given the task of rebuilding the top end, while S&J Cycles in Santa Rosa, took care of the bottom end. 

Photos courtesy of Pipeburn.

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Dynamic Flow

The Ironhead motor is fed via a Mikuni carburetor sporting a custom velocity stack. As part of the learning process, Smith acquired a lathe and turned the stack from a piece of four-inch 6061 aluminum round stock. Regulating the stack's airflow 1920’s Zenith dynamic microphone grill. Other meticulous details include a handmade rear fender and a vertical license plate. 

Photos courtesy of Pipeburn.

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Custom Shift

Smith took a minimal and functional approach to the build. The process included custom fabricating almost all the controls including the footpegs, shifter, mechanical rear brake linkage and headlight mounting bracket. From the top view, the XLCH's shifter is visible on the right-hand side. To comply with DOT regulations, the Motor Company moved the shifter to the left side in 1975. 

Photos courtesy of Pipeburn.

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Cutting and Bending

All good choppers need a sissy bar, and Smith's build was no exception. The bar was one of the first components he made. Using string guidelines, Smith drew numerous full-size renderings before he started cutting and bending. Thinking ahead he explained the design, “I wanted the lines of the cross brace bars to mimic the lines of the stripes on the AMF tank logo.” 

Photos courtesy of Pipeburn.

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Vintage Story

Part of Smith's vision included an AMF-era tank with patriotic stripes. After a lengthy search, the perfect candidate was located. The tank showed its age with gas marks and eroded paint, but it had just the right amount of history. Smith explained, “These old parts all have a story — that’s what’s exciting to me — combining vintage parts with new fabrication.” 

Photos courtesy of Pipeburn.

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Detail Course

Personal touches abound on Smith's build. The taillight is from a warning panel with a custom machined housing and a Turkish coin as the backing plate. The eclectic details mark the build's trajectory. Starting with a basket case Ironhead and a few hand tools, Smith graduated to a shop with a lathe, drill press, and a TIG welder. More importantly, he gained a wealth of knowledge at the school of 'do-it-yourself.' 

Photos courtesy of Pipeburn.

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