My friends, this is going to be a difficult post.
Just uploaded plenty new pics of the recent work done on the new rods, barrels and crank, you can take a look below. But, I'd like to share with you the sad side to this story.
As you know, all of these new parts are destined for the very first customer build.
A rare person indeed, now a friend more than a customer, a lifelong motorcycle enthusiast and collector.
In the initial discussions of options months ago, I mentioned to him these new products I had in mind and he immediately was on board to try them out, knowing that they would be the very first test prototypes being built. That is the spirit of the true enthusiast, willing to take the risk.
And, here is the cruel twist.
He was recently diagnosed with stage 3 cancer.
The goal is to simply get this machine done as quickly as possible and get it to him so he can ride it, enjoy it, let it hopefully be therapeutic, medicinal in some way before health issues make it hard or impossible to ride.
I can't deny that fatigue is certainly hindering the brain and body from performing to full capacity and stupid mistakes brush past, dangerously close.
Without making any melodramatic statements, all I'd like to say is that your positive thoughts, wishes, vibes will be greatly appreciated, even if unspoken.
I apologize sincerely for the overdue replies to messages, they will be addressed as soon as time is available. In the meantime, your patience is deeply appreciated.
With best wishes,
Aniket

A few shots from the crank build. A long, laborious, painful task , includes machining flywheels, making new custom crankpin, assembling, balancing and truing. Crank is complete and ready for installation, final runout on this crank is <.001.

The new alloy barrel castings posted previously have now been completed. These took a lot more work than estimated. The key feature of this design is tappet access incorporated into the barrel. Stock barrels on the V twin require tappet adjustment through the rocker covers, this design retains the quick access. Castings were bored to shrink-fit cast-iron sleeves. Sleeves were bored and honed after installation. Both cylinders are now complete and ready for fitment.

Another new part that will be installed and tested in the current build. These were machined from high strength 7075t6 billet - 65,000psi yield strength, often used in aftermarket performance rods. I beam cross section area, height, flange width, all increased. Material added above small end. Shot peened after machining. Rod weight 320gms as shown, without big end. These are fitted with a heavy duty needle roller bearing, another experiment in the search for affordable alternatives to the stock floating bush.