Full Circle – The Muscle Racer 2, a Harley Davidson Sportster

Setting the scene

Generally in life issues come full circle. Permit me to sidestep and take you again. On a sunny day in November 2017, I wished to unwind from a scientific convention I attended in Miami, Florida. On the lookout for shade I ended up at Brothers & Brawlers, the place I discovered an attractive area, a superb cup of espresso, and an environment that made me need to keep till the tip of time. The grey concrete, black metal, and pure wooden gave it an industrial vibe, but the area felt gentle and leather-based seats and sofas had been tender and nice. The helmets, equipment, and clothes displayed tickled my fancy. A few customized bikes had been on show. That is what most of us see in our creativeness once we hear ‘man cave’. Sebastian Ramirez, proprietor and founding father of DiRocco Eyewear, supplied the of completion. He arrange the area as a residing commercial that you might breathe, odor, and style.


Subsequent, I noticed a bike that planted a seed in my creativeness. The seed of constructing a customized bike (on the time I owned a virtually bone inventory 2010 Triumph Bonneville T100). As we talked concerning the area and the idea, a van pulled up. Chet and colleagues jumped out, a motorbike rolled in. And we ended up giving them a hand in placing it up on a platform for show. The bike was a Triumph Thruxton, designed by a well known, dapper, masked rider, the primary within the Snaefell collection by Cohn Racers. Little did I do know that 5 years later, I might write about one other collection of bikes the Spanish-born, Miami-based builder Chet P Ilzarbe would produce.

Beforehand we featured their Harley Davidson XR1200X Muscle R collection. Now it’s time to replace you about their new line, the Muscle R2. In a second half, we gives you extra perception into Cohn Racers and its founder.


First, some background. The Muscle R2 got here out of the unique Muscle R, as most racers and builders can agree: there’s at all times room for enchancment. Throughout the manufacturing of the unique Muscle R, Chet began figuring out and testing these small enhancements. Adapting, modifying, and testing on a bike one builds for one’s personal storage is a part of the method. Nonetheless, that is out of the query once you set your self excessive requirements for bikes you construct for shoppers throughout the globe. So the place can you’re taking these enhancements, and specific your problem-solving abilities? Right, in a second collection, the MR2. The income from the primary collection had been used to rent Joan Mataro and Anton. The primary a mechanical engineer with a ardour for bikes, the second a carbon fibre specialist, who labored at Scuderia Toro Rosso and Koenisegg. The remaining funds had been invested in equipment, together with 3D scanners, software program and 3D printers. This setup permits for reverse engineering, speedy prototyping, and evaluating knowledge. 

Nonetheless, regardless of the enhancements within the store, the unique idea remained: a Harley Davidson Sportster with actual energy, correct brakes, improved dealing with, and a chic but imply stance reflective of its rider. To enhance the dealing with, the staff engineered a brand new body with optimised geometry for superior consolation and rideability. Secondly, rising the facility output of the engine and lowering the burden resulted in 26% extra horsepower and 22% much less weight, additional enhancing each dealing with and rideability.  


Once more, a Sportster mannequin supplied the engine and body as beginning factors. They 3D scanned each and included an extra XR1200 body as nicely. Utilizing the ensuing digital mesh with tens of millions of recorded knowledge factors, different elements could possibly be added digitally. After including the suspension and wheels, the primary prototype was simulated to check behaviour and ergonomics. A number of prototypes had been then printed from PETG plastic. After a number of iterations, they settled on a 3-piece meeting that bolts along with 4 M8 bolts within the entrance, and 4 M10 within the again. Grasp welder Josh Lewis constructed a welding jig to completely align each element previous to meeting. Thus, any alloy can be utilized to weld up a body within the good geometry. Presently they use Titanium GR5 future MR2 homeowners. Utilizing these excessive grade alloys ends in a closing body weight of lower than half of the unique sportster body. 

Weight Financial savings

Furthermore, utilizing Titanium all through the bike ensures the aforementioned weight financial savings. The initially metal entrance and rear axles, head stem, and exhaust are all newly product of titanium. Even the unique metal bolts are changed with titanium bolts. A swing arm of billet cnc aluminium is a chunk significantly onerous to return by, often restricted to MotoGP and elite racing. Due to this fact, the staff designed a 5-piece that’s welded collectively and adjusted to the shopper’s peak. It gives energy, reduces weight, and introduces simply the correct amount of flex. Once more, digital simulation was used to finetune these parameters into the ultimate design. 


Additional enhancing the dealing with, inventory suspension is swapped out for totally adjustable Öhlins FGRT 200 collection forks in proprietary cnc billet aluminium triple clamps and twin rear shocks. The spring charge and valving might be adjusted to each shopper’s specs. 

Wheels & Tyres

The inventory Harley Davidson hubs spoked with stainless-steel and lavcd with 18×6.0 and 18×3.5 rims, give the bike a little bit of a flattrack really feel. Shoppers have a big selection of choices for tyres with this configuration, but twin sport tyres appeared to be a preferred alternative for the primary collection. Rims product of carbon fibre, titanium, and aluminium are at the moment below improvement and might be out there as an possibility solely to MR2 homeowners.

The Powerhouse

Driving all this ahead is a 100HP energy plant primarily based on the unique motor. One of the difficult elements to engineer and manufacture is the proprietary down draft air consumption system. The aluminium manifold is cnc-milled from a stable block on a 6-axis machine. Oxygen is supplied by way of two lovely mesh coated ducts within the entrance. Gasoline is supplied from a laser reduce and bent 2mm aluminium sheet that’s welded and coated with a carbon fibre shell. A small oil cooler was built-in to cut back oil temperature and the unique oil tank below the seat was saved to make sure a ample quantity within the system. On the again finish of the engine are two titanium headers with pie reduce bends, giving it a rainbow array of colors after a number of heating cycles, topped off by two Akrapovic exhausts. For future shoppers keen to commerce in some reliability, the output might be elevated even additional.


To sit down atop this powerhouse, shoppers should decide their very own disguise for the handcrafted upholstery. The hides are sourced from Scotland and artisans then craft the seat, tank strap, and non-obligatory different elements to make sure unity all through. This ties each ends collectively and exhibits the extent of detailing that goes into these bikes!


Carbon fibre is used all through the construct. Their inhouse specialist with a formidable background has optimised the method of impregnating carbon fibres with resin and curing it in an autoclave (assume: industrial strain cooker) to make sure the optimum resin to fibre ratio. This makes for a  very gentle and concurrently very sturdy materials. Over 20 elements on the MR2 are made this manner. In our eyes, this intensive, costly course of is justified by the end result! What a visible spectacle to look at!

Different aesthetically pleasing particulars are the lights and indicators. They’re totally built-in into the bike. The tail, brake, and indicator lights are built-in into the fender with simply two elements! All wiring is rigorously hidden from sight, indicator wiring for instance is built-in into the handlebars. The gauge is backlit in blue, simply because the buttons, a refined and chic contact that improves working them at nighttime. That is one other indication that the builders prioritised the rider’s perspective. The gauge shows analog revolutions and all different data digitally, conserving it clear and timeless. The entrance of the gauge is roofed with carbon that crowns the bike with a wax mould solid, polished 24K emblem. 

Final name!

Solely 99 bikes might be constructed, based on shopper specs. Many of the choices which might be modified inhouse are included. Changes might be made to the experience peak, suspension stiffness and different small particulars that can guarantee probably the most snug match to the shopper. Particular needs will also be catered for. Pricing is progressive, the primary one beginning at $45,000 USD.
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