A Frame Is Born….
….and it’s Very Good
The specialization is classic HD frames, which are virtually exact replicas of the OEM Harley‑Davidson frames, including all castings with correct casting numbers, supplied only by VG.
We visited the company, based in Hengelo, The Netherlands, to see “A Frame is Born” in action. There is increasing demand for older Harley‑Davidson frames, especially Knuckleheads and Panheads. These frames are regularly restored and rebuilt in their original state, sometimes requiring a completely new frame, while in other cases only sections need attention or repair.
The knowledge, specialization, and careful craftsmanship for these old models have steadily grown, and at present, VG Classic Frames & Parts is more or less the only supplier of replica vintage frames that are recreated so accurately according to standard specifications.
“We are prominent in the market with classic HD frames, but we are also constantly busy improving details and finishing touches,” says Herman of VG Classic Frames & Parts, who has been running the company for decades in its 500 m² facility.
We Recreate History
“Today we are going to build a 1948 Panhead frame for a customer,” says Raymond, taking the work order and carefully reading the specifications. “It has to be an exact replica. Sometimes a customer wants a different steering head angle or another modification, but today we make this entirely as it was made in 1948.”
In the warehouse, all parts needed to build a frame are in stock. Raymond grabs the tubes, castings, and the headstock and explains: “In the past, Harley‑Davidson used different heads, partly because forks in the thirties and forties had more rake.” He points out minimal differences, and as with every frame, every detail counts.
With most pipes, parts, and castings collected, Raymond sets the frame mold. It is an advanced tool, indispensable and adjustable for all possible specifications and dimensions. The mold includes dozens of extra parts for different configurations. The seat tube is placed first, then one of the most important castings—the head—is set at the correct angle. Next, the two down tubes are placed, followed by the castings that form the “bend” in the frame tubes, including attachments for sidecar use. Two bent pipes pass under the engine to the gearbox. The front engine support, also a casting, has already been positioned and is being welded.
Raymond takes another casting and places it on the seat tube. Using a laser, everything is checked with extreme precision. At the rear, gearbox mounts are welded to the tubes. From there, both tubes run diagonally to the rear axle. Castings are used just as in original frames of that era. The frame is already highly recognizable.
Every operation—adding a casting or tube—requires different parts on the mold. Everything is fixed firmly and measured multiple times before welding. The heavy-duty mold rotates with an electric motor, making it easier to weld all parts. The upper frame tube, from saddle post to headstock, is added next, including mounts for the engine, cylinder head support, and fuel tanks. Plates clamped around the lower frame tube form the footboard mounting points, created in a special mold with a press. Some welds are TIG, some MIG-MAG, depending on the material.
All frame tubes used for OEM-spec frames are pre-made in small series and bent to the correct radius. Where necessary, “bungs” (plugs) slide into the castings, forming stronger connections. “This saves a lot of time,” Raymond explains. “All we have to do is grab the necessary components and assemble them according to the customer’s wishes. Fabricating everything separately would take much more time.”
“In addition to all the pipes, we also have the castings in stock,” Raymond continues. “We are also exploring ways to make the castings even more detailed to match original factory specifications.” Herman adds, “We work with many companies and dealers. VG Classic Frames & Parts is a team player; we share knowledge.
After this, the frame receives the pipe running between the bottom of the head and the upper frame tube for added strength. Less flex makes the frame stiffer, improving handling. Again, everything is measured, the mold perfectly set, and then welded. Raymond welds while Herman prepares the next parts. The mold is set for the rear section, and tubes are shaped to fit precisely at the front. These are welded to the upper frame tube and to the castings at the rear, with the cross connection welded almost simultaneously. It looks like Lego—everything fits perfectly—but experience, special equipment, machines, techniques, and materials make it work.
Finally, the frame is almost ready. It is rotated and welded to perfection, which is an art to watch. After final checks by Herman and Raymond, the 1948 Panhead replica frame is finished—indistinguishable from the original.
In addition to frames, VG Classic Frames & Parts produces castings, brackets, supports, tubing, mounts, and more. All these frames and parts are avilable in our shop. Enjoy!
Text & photography Onno “Berserk” Wieringa – madnessphotography.