The Fabrication Process

The design and fabrication of a custom vehicle can have many factors to consider. The client might have some specific expectations. The preferred powertrain, suspension and drivetrain components will suggest certain design features. The final use of the vehicle must also be taken into account. On some occasions the client will simply say, "Just do what you guys do, surprise me"

We have found that the use of pre-visualization is mandatory, and use various computer programs to keep all parties informed about the progress of the design before any components are formed. In addition to keeping everyone informed, dimensions are developed as the expected form takes its virtual shape. The 3D computer program that helps to visualize the shapes, also insures that all components have proper clearances for powertrain and running gear components.

Once the design has evolved to a certain degree, tooling can begin. Our in-house fabrication includes the forming of the bodywork panels and the tooling required to complete them. For the compound curve sheet metal we prepare a buck. This helps insure that the panels are consistent with the computer model, and that both sides are symmetrical.

It might seem like this is excessive preparation. In the end, much time is saved in arriving at a finished project that everyone is happy with. Potential problems and opportunities are revealed before materials and labor are invested. The process is elastic. Simple components can be left un-digitized, and figured out later as required. Also, revisions can be made after construction has begun, but we really hate to do it.

After the design and tooling are mostly complete, the fun begins! Now we use big hammers, make a lot of sparks and carve out some really cool stuff!

On motorcycles, the gas tank is the best place to start. It is the identifying aspect of the design, and will probably take the longest to complete. We use 16 guage steel. The panels are usually first beaten into a sandbag. And I must insist, there is nothing better than problems you can fix with a big hammer! Then the panels are smoothed out on the english wheel or air hammer, or both. The panels are always matched to the buck, and finally tacked up.

This process proceeds until all the panels are complete. Then all components are welded up. The welds are buffed off where appropriate, and a final polishing is given to all bodywork. Most clients really lament burying the formed steel in filler, primer and paint. Yet the quality of the entire project is insured by keeping everything shiny ands new.

Sounds simple, and it really is. However, keep in mind that the V Bros. have about 60 years of collective experience in vehicle fabrication, design and product manufacturing.

We've been around the block a few times. Doing it on one of V Bros. projects is much better!