Tyler Malinky’s Panhead Project Part 3

11 Tyler used cut-off wheels on a hand grinder to slice and miter the tube sections for his exhaust, but we’ve seen hacksaws and band saws applied for this process as well.

12 After roughing out the opposing tube ends to create a given joint, it’s helpful to fine-tune the joint interface by shaping and de-burring every cut on a sander. If you don’t have a sander, a flap disk on a die grinder will also do the job.

13 The goal with whatever combination of cutting and mitering tools you choose is to create seams that are airtight. Tidy weld beads require less grinding, sanding, and polishing before plating, and this helps create a smoother-looking finished pipe.

14 Tyler’s pipes are handmade, distinctive, and original. Isn’t that what every chopper is supposed to be?

15 In keeping with his British fixation, Tyler chose twin Amal carbs for his Panhead. Underground fabricator Trumpnut Nick from northern Nevada makes this twin-tube contraption that connects the twin mixers to an S&S Panhead manifold.

16 The weight of two manifolds and two carbs gave Tyler pause for concern, so he fabricated this support bracket using scraps of stainless-steel rod from other parts of his project. Choppers have an uncanny ability to vibrate themselves silly; so little components like these add both structural integrity and visual intrigue.

17 Tyler is a clever builder, but even he knows his limitations. Professionals handled things like plating, painting, and polishing on the Lowbrow Panhead project so Tyler could focus on things like getting these finicky Amals to pump fuel into his rebuilt mill.