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V-Twin Heritage. Modern Dominance.

This project involved the complete transformation of a 2000 Redneck Chopper from its traditional, old-school aesthetic into a aggressive, modernized, blacked-out pro-street machine.

 

The build successfully balances striking visual minimalism with high-end mechanical upgrades, replacing dated components with cutting-edge performance engineering.

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Detailed Component & System Upgrades

1. Powertrain & Drivetrain

  • Engine Upgraded: Extracted the legacy RevTech motor and swapped in a high-torque, ultra-reliable S&S 111ci V-Twin Engine as the center powerhouse.

  • Primary Conversion: Replaced the enclosed wet primary with a BDL Open Belt Drive System, creating a raw mechanical look and eliminating primary oil maintenance.

  • Final Drive: Upgraded to a high-tensile Kevlar super-strong final drive belt to reliably manage the increased power output.

  • Aspiration & Tuning: Installed a premium Performance Machine Carbon Fiber High-Performance Air Intake to maximize airflow, paired with a custom-tuned carburetor for seamless throttle response.

  • Exhaust System: Preserved the distinct lines of the original exhaust by stripping and performing a full custom re-chroming process to provide a sharp, mirror-finish contrast against the dark engine block.

2. Chassis, Fabrication & Bodywork

  • Frame & Structural Foundation: Fully stripped the bike down to the bare frame for media blasting, followed by a durable Gloss Black Powder Coat.

  • Bodywork & Paint: Prepped, sealed, and painted the front fender, rear fender, fuel tank, oil tank, and headlight bucket in a deep Gloss Black Automotive Finish.

  • Wheel Refurbishing: De-chromed the original wheels via a specialized chemical stripping process, then powder-coated both the wheels and front hubs to Gloss Black.

  • Custom 3D Fabrication: Engineered and 3D-printed specialized, high-durability components to replace weathered or broken factory pieces:

    • TPU Custom fuel tank mounting spacers to eliminate the vibration

    • TPU Fuel cap sealing gasket to block fuel leak

    • Under-seat clamps redesigned and printed from ABS filament for durability

    • Dedicated internal module holder box to keep the battery tight

The Fuel System Challenge: Sourcing the Aero Cap

During the teardown, the original aircraft-style Aero fuel cap was flagged due to deep surface scratching and severely degraded chrome. Because standard motorcycle fuel caps do not fit the unique fabrication of the 2000 Redneck Chopper tank, a domestic replacement was impossible to find within the US market.

 

To maintain the build's elite quality, a specialized international search was launched. A brand-new, exact-fit flush Aero cap was successfully sourced and imported from a specialist manufacturer in the United Kingdom. This was paired with a custom, house-designed 3D-printed fuel cap gasket to ensure a flawless, leak-proof seal against the fresh gloss black paint.

3. Controls & Braking System & Electrical

  • Brake Calipers & Masters: Upgraded the entire stopping system to premium Performance Machine (PM) High-Performance Calipers and matching master cylinders for exceptional bite and feedback.

  • Lines & Cables: Swapped out all aged cables for stainless steel black-jacketed lines (Front/Rear Brake lines, Clutch line, and Throttle cables).

  • Hand & Foot Controls: Purged all old-school chrome accessories, replacing the grips, hand levers, mirrors, and forward foot controls with modernized, textured black billet components.

  • Stabilization: Replaced the unstable, legacy spring-loaded kickstand with an adjustable, heavy-duty modern chrome kickstand to ensure secure parking geometry.

  • Battery Box Fabrication: Custom-fabricated a heavy-gauge steel battery box, finished in matching black powder coat to seamlessly blend into the lower frame junction.

  • Power Upgrade: Abandoned the heavy, low-efficiency AGM battery in favor of an ultra-compact, high-cranking Antigravity Lithium-Ion Battery.

  • Starter System: Installed a high-torque modern starter motor to ensure reliable, effortless ignition of the high-compression 111ci S&S power plant.

The Result

A relentless, street-dominating machine that commands attention wherever the rubber meets the asphalt. By replacing vintage instabilities with race-grade braking, high-torque lithium power, and the brute force of the S&S 111ci engine, this chopper has shed its dated skin. Stripped of its traditional chrome and draped in an uncompromising coat of gloss black, it stands as a testament to precision engineering and aggressive styling. This isn't just a modified chopper; it is a completely reinvented, bad-ass modern cruiser built to roar, reign, and rip through the streets with absolute authority.​

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