Written by Marlon Slack
Dan Moto have been building exhausts that please owners and piss off neighbours for the last ten years. And as their catalogue of bike parts expands quicker than a Harley owner?s waistline they?ve decided to showcase exactly what their team of fifty staff can do ? by building a custom Sportster completely in-house. A Sportster that has its emphasis firmly on sport.

And what better way to show what Dan Moto can do, than by modifying one of the most ubiquitous cruisers in the world" ?We wanted to take the most popular engine available and build a complete bike around it,? head of DanMoto, Wei Liya says. ?It had to go fast and show off our fabrication skills in the process, with everything being made in house with the machines and equipment we use in daily production?.
With that, Wei and the team purchased a stock Sportster online with the sole intention to butcher it for its engine. Just about everything else on the bike would go. So, with the powerplant out and on the benchtop, the team calculated the overall frame geometry they wanted. And then they made a jig for the frame and swingarm, which was designed in CAD.

All the important parts ? the steering head, engine mounts, swingarm mounts and every little bracket mount and adjuster was CNC machined out of billet aluminium. When that was completed, the frame was fitted, welded together and then powder coated, before work continued on the suspension.

The Dan Moto Sportster runs front ...