Custom Builder Sansone

There are many reasons motorcycle mechanics, designers, and aficionados get into building custom choppers. For many, they simply have a design in their head and after years of biking experience, whether it be working on the machines or just riding them, these mechanically inclined entrepreneurs decide it's about time to build their dream bike. Then of course, you have builders like Richard Sansone who decide to make a custom because they're tired of being ripped off.

Sansone has been building parts for custom shops and Harley-Davidson dealerships for 23 years, but he started working on bikes long before that. In fact, at age 10, Sansone got his first dirt bike, and that's when the infatuation really took hold.

By the time 1980 rolled around, Sansone was able start his own business designing parts for companies all over the East Coast. But, according to Sansone, almost every time he would design a trick component, it would end up in a magazine on someone else's bike with their name on it. Since Sansone made a custom part for nearly every aspect of a motorcycle, he decided to build his own chopper, and this time his name would be on it.

The Sansone bike on these pages is the result of this effort. Inspired by his compilation of parts, this bike's physical appearance and techno-trickery took on a life of its own.

"The bike is a reflection of the type of parts I've been designing over the years," the Massachusetts-based builder explains. "It's a combination of all my different parts, and I just decided to put them all on one bike. I made them all work together."

Of course, to get to this point he had to take two steps back in order to make one leap forward. Sansone let go all of his employees and made it a true one-man operation. His solo debut is the epitome of "if you want something done right, then you have to do it yourself." And we mean everything.

Sansone's hands were the only ones to touch this bike. He designed the parts, rendered them on a 3-D CAD program, fabricated the components, bent the metal, and made the molds for the carbon fiber/kevlar panels. He wired the bike, tuned the engine, built its hydraulics, and the list goes on.

The components on this motorcycle give it the appearance of less is more. However, in the Sansone design, more is more—it just looks like less. The myriad of unseen parts starts with the variable ride height made possible by an electric/hydraulic suspension. This design eliminates the need for a kickstand because when the suspension is fully retracted the bikes frame is kissing the ground; the zero inches of ground clearance keeps the ride firmly parked and, according to Sansone, it's more stable than most kickstands. The hydraulics are actuated with the push of a button (one front, one rear), and a rider can independently lift the bike's front and rear ends off of the ground to its riding height. The real genius behind this suspension is that it can be raised to its cruising height in just a couple of seconds.

"It goes up nice and smooth," Sansone describes, adding that it can be adjusted while the bike is in motion. "It's a very fast system. Any type of air system you have to wait and wait for that thing to build up. This is hydraulic, so it's much faster and has independent front and rear controls. There's years of development put into this."

Sansones use of aerospace materials in his bike in order to make the low, sleek ride feel like a Calvin Kline model in an industry of Jenny Craig candidates. Lightweight carbon fiber is used for the gas tank, front and rear fenders and seat base, and the frame is constructed from 4130 chromoly steel tubing. Sansone claims that his prototype is 200 pounds lighter than your average custom bike.

A Harley-Davidson Twin Cam 88B engine complete with a 95ci big-bore kit gives the custom chopper plenty of power to compliment its gnarly look. A Mikuni HSR42 flat-slide carburetor with velocity stack controls the fuel flow while a custom Sansone exhaust system expels the waste. Sansone billet aluminum foot controls actuate the brakes and five-speed gearbox

The clutch and hand levers are recessed into the bikes handlebars so that all of their pivot points are hidden. Also tucked away in the handlebars are the turn signals. When in use the signals pop out of the handles for as long as needed and then retract back. All of the wires and cables are hidden within the bike's frame.

Sansone plans on hiring on more people in order to manufacturer 20 bikes based on this prototype design. After that project is complete, he will start a new design. Of course, these creations aren't for the faint of heart and financially un-graced. In fact, Sansone designed this bike for those who have money to burn.

"This bike was designed for wealthy people that can afford this motorcycle," Sansone points out. "These motorcycles are over $70,000. There are so many different things in this bike that make it very time-consuming to manufacture, and I went after a market of people that can afford an expensive motorcycle."

After several decades of being behind the scenes on other peoples projects, Sansone has finally decided to step out into the spotlight and he did so in a big way. He's already sold his prototype and his preparing his shop for production.

For more information on Sansone Motorcycles go to www.sansonemotorcycles.com

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