Becoming a vehicle builder

In Sweden where this fairytale takes place it is possible to make your own vehicle from the ground up.
A unique possibility that not many countries offer.
This is possible because a massive work done in the eighties by a team of people that later became known as SFRO - Sveriges Fordonsbyggares Riksorganisation
(Translated to English its something like SVNA - Swedish Vehiclebuilders National Association.)
This is an organization with part time voluntary tech inspectors around the country.
There is also a book available from SFRO with many tips and tricks to succeed with your build.

The SFRO handbook

This opportunity to become a vehicle builder have many used over the years and so will I.
The process have three steps.
One: The build inspection by SFRO.
The first one that should occur some way in to the project.
The vehicle shall have basic construction ready to check things like steering, rake, trail, suspension travel, measurements, material quality and of course welds.
At this stage no paint is allowed but protective primer is OK.
It is also at this step the vehicle starts to exist and the vehicle will have it's VIN number.
The 17 digit long VIN number is partly free to choose by the builder, the 8 last digits is up to the builder to choose.
At this stage its also time to name the build, this is also up to the builder to choose.
My bikes name became "Bombus Speedster"
Two: The second and last inspection by SFRO.
At this stage the build is all ready and things like lights, markings and positions, how it handle's when driving are tested and finally the sound level certification.
The sound level is just 84dB and is quite hard to reach but with some serious mufflers will most often do the trick.
Three: registration inspection.
This stage is done by the national tech inspection and is basically a light version of previous step.
This is also when the vehicle gets its registration number.

And after passing these three steps you have built your own vehicle.

It's possible to make quite amazing builds this way.
The main vehicles made this way is custom motorcycles (HD based), Hot Rods and Cobra/Super 7 replicas but pretty much anything is possible to build this way.

For example, I have a friend that bought a Porsche Boxter and a hacksaw. Sawed the body of the Porsche and welded on a VW Beetle body instead and that is now road legal and counts as a new vehicle, The Bubster.
You can follow his build thread here at the site REJSA (In Swedish)

Here in a early stage starting up in the garage.

Losing 90mm

Some measurements made me realize that handlebar could be a bit more narrow.
Rigged up the complete handlebar in the wise and the measure begun.
25mm of each end plus the 20mm end plugs.
A total of 90mm(3,5") was the verdict.

The shortened handlebar in the wise

The lost witdh, 20+25+25+20 => 90mm(3,5")

Tech inspection one

A HUGE step on my path of building my bike have passed !
Tech inspection one went according to plan. Seems like I've made wise choice's and got help and info from experienced people along the way but off course because also a great dialog with the tech inspector. I had several of solutions I wanted to discuss and it went great, now I have enough good input to continue the build to the end. I will also keep in contact with the tech inspector if (when) I get in to issues along the way.
Maybe the biggest issue I had was the one with the turbos.
But we decided that I finish the bike first and does the final inspection with stock 1200 engine and next(?) year I will do a upgrade.
A much smaller procedure then the one I'm doing now.
And also there will most definitely be enough issues along the way even without the turbo/EFI install so I will do than nice and easy next winter.

But first up, deconstruction again...

Final mockup

Complete final mockup done and looking fiiiine. Everything worked great and all went according to plan with all the details I've made. Next step tech inspection one (of three) and then teardown again. After that I will paint the frame black and put everything back again. The big four steps remaining are seat, wiring, oil lines and brake lines. Then its just the endless small "last things" that remains.

So happy how it turned out.

Distance in the lathe

After i finally figured out the measurements I had to do some final machining on the sprocket spacer.
Both diameter and thickness got some treatment in my little trusty lathe. 

After a while the bench looked like had found a silver mine.

Primer

So the day came that i didn't believed existed, when the frame was "done".
I rigged it up, cleaned it and started to lay some primer on it.
Two thin layers. First I thought I could use this color the first year but I think I have to paint it in some darker color, black?
This is just a temporary paint I will use the first year(s) until I feel the bike is ready for real then it's time for its final paint, probably black powdercoat.
It's not even allowed to paint the frame before tech inspection one, but protective primer is OK.
Tech inspection one is just around the corner so I will probably pull it apart again after that to paint it.
Not so labor intensive but still some work.
I might regret it later if I go for just the light primer.

Rigged up, completely cleaned with acetone and ready for layer one. 

Primer done