Article And Photos By: Alex Scott
Melted tire stuck to burnt wheels, charred frontend stripped with rust, and a scolded engine detached and disassembled. There could be, perhaps, no other scene that Doug Balko could stumble upon that would better inspire a ground-up build on a half-century old bike. But, out of tragedy and a bit of bad luck, came the opportunity for Doug to realize one of his dreams, one that thousands of bikers share, a chance to completely restore a 1949 Harley Panhead.
The bike was originally owned by Doug’s friend and coworker, Mike. A fire tore through the shop of one of Mike’s friends, and unfortunately, was razed to the ground. The Pan just happened to be there and was badly damaged. Seeing no other alternative, Mike locked it away in a shed behind his house. The bike’s hiatus was longer than expected, and spent the next 20 years undisturbed. Doug and Mike both work together at NASA and after nearly 15 years of talking about it, Doug finally bought the bike and decided to raise this Pan from the ashes once again.
Doug and Mike both got into riding at a young age. Doug started out on dirt bikes and at age fifteen he got his license and a road bike. His first Harley came at age twenty-two: a 1976 Super Glide. From then on out it was only Harleys for Doug. Mike has had his share of bikes from BMWs to Harleys as well.
When Doug went to pick up the Panhead, he said it was like walking through a motorcycle museum. Now that he had the old Pan, he was finally able to start the build on the vintage bike; literally from the ground up. Doug brought the bike’s remains in a box back to his house to survey the damage, but the autopsy was not looking too good. The ’49 powdercoated frame was still in good condition, but not much else. The engine and tranny were completely disassembled and he began to scrape burnt rubber off the metal.
Despite the glum outlook, Doug started right away to get the bike back in flight. First, was to put the engine back together. Working on weekends and after work, he began the project in his garage in Pasadena, Texas. Parts weren’t easy to come by and scouring swap meets and Web sites soon turned into a daily routine. Doug hunted down some of the pieces he was looking for at the J&O swap meet. He says Rob Osborn, of Osborn Cycles, was very knowledge and beneficial in helping him find the parts he needed for this build. The Phase 3, 2” drive belts, new controls and a new suicide shift all came from Osborn Cycles.
Parts were coming from everywhere. Doug rebuilt a carburetor he bought on eBay, as well as the front wheel. He found a stock DNA Springer frontend, and the rear wheel came from V-Twin Cycles. Like a man possessed, Doug finished the build in just under 5 months. Finishing touches came from a can of flat black spray paint and some pinstriping found on eBay. The paint was going to be temporary; a quick job most bikers could relate with to get the bike on the road! Doug got so many compliments when riding around with that $5 paint job, he decided to keep it. And how could you blame him.
The bike already had the Morris magneto, which Doug sent out and waited patiently, as that was the last missing piece of the puzzle. He says the grand moment was when this sleeping beauty roared to life , and it sounded like a Texas thunderstorm. Doug’s wife, Jimisu, came running out of the garage to watch the culmination of the hard work, passion, and the love that went into the bike. Doug immediately rode it to work to show his buddy Mike, who was very helpful during the build, what had become of the old bike. Mike was impressed, to say the least, and was glad it went to a good home.
The bike is a not-so-quiet reflection of its trials and tribulations. With red pinstripes and flat black paint resembling the flames and soot that tried to destroy it, this Panhead rose like a phoenix from the ashes, and who better to send it up and away then a NASA man himself.
Burn It Down ‘49 Pan Tech Sheet
Owner: Doug Balko
City: Pasadena, TX
Fabrication by: Doug Balko
Year: 1949
Model: FL
Time: 5 Months
Value: Priceless
Engine
Year: 1949
Model: Pan/Shovel
builder: Doug Balko
ignition: Morris Magneto
displacement: 86” S&S Stroker
pistons: S&S heads: ‘66 Shovel
cam(s): Sifton 440
carb: S&S Super E
air cleaner: Bobber
exhaust: CCI
primary: 2” Phase 3 Belt
transmission
Year: 1949 Ratchet Top
Make: HD
shifting: Jockey
Frame
Year: 1949 Wishbone
Make: HD
rake: Stock
stretch: Stock
Front end
type: Springer
builder: DNA
extension: Stock
wheels
Front wheel:
size: 21”
tire: Avon
brakes: Huh?
rear wheel:
size: 16”
tire: Avon
brakes: Drum
paint
painter: Doug Balko
color: Flat Black
type: Rattle Can
chroming: None
Graphics: Doug Balko
Molding: None
accessories
bars: Drag Specialties
risers: DNA
hand controls: Drag Specialties
Gas tank(s): HD 3.5 Gallons
Front Fender: None
rear Fender: 5” Flat
seat: Bates
Foot controls: J&P Cycle
oil tank: Spun Aluminum
Mirrors: None
headlight: J&P Cycle
taillight: Sparto
speedo: None
photographer: Alex Scott