What goes into building a genuine vintage custom motorcycle? On the Proven Performance Podcast, Howard Kelly from S&S Cycle sat down with Chris Callen of Cycle Source Magazine and Brian Klock of Klock Werks to unpack the stories, sweat, and creative tricks behind their unique P-Series bikes for the SNS Vintage Tour. Their tales aren’t just about nuts and bolts; they’re about passion, heritage, teamwork, and sometimes, a little bit of luck.
The Story Behind These Vintage Machines
There’s more to these bikes than shiny paint and old-school lines. Both Chris and Brian brought deep personal and historical meaning to their builds, honoring both motorcycle history and family.
Chris Callen: From Long Choppers to Vintage Customs
Chris Callen isn’t just known for his wild 9-foot choppers. This project pushed him outside his comfort zone and into the world of post-war American customs. Back in the day, returning GIs took what they had and made it their own. They cut down the family panheads, knuckleheads, and flatheads, stripping off weight, making the bikes lighter, faster, and a little cooler.
This spirit inspired Chris to resurrect what looked like a 1949 Panhead in stock trim—but with much more work behind the scenes than meets the eye. “This was the most amount of customizing I’ve ever done,” Chris admitted, even though the finished bike appears factory. His goal? Build something that told a story—not just for himself, but for a new generation who may not know where custom bikes came from.
Brian Klock: “RK’s 61”—A Tribute to Family and History
Brian Klock’s build was personal from the start. He paid tribute to his father and their shared love of motorcycles, building a “61 Panhead” as a nod to a special family photo from August 1966—his dad, headed to Sturgis just before Brian was born.
Here’s what shaped Brian’s build:
- Photo of his father on a white-and-red 1961 Panhead, taken a month before Brian was born
- True-to-history color and emblem choices honoring the rare “reverse” paint option his dad’s bike had
- Four stars on the battery box for Brian and his three brothers—all Dallas Cowboys fans.
- Personal nods to every important piece of his family and upbringing
Brian set out not just to replicate a memory, but to create a ride his dad would love—a fusion of tradition, respect, and modern power.
The Art and Challenge of Custom Building
Turning ideas into metal and rubber takes more than passion. Both builders faced unique hurdles and made creative choices to blend vintage style with the performance of new S&S engines.
Chris Callen: Restoring a 1949 Panhead From the Ground Up
Chris started with a heap of parts he’d bought ten years prior—barely more than a “bike in a box.” Here’s how he brought it to life:
Frame Restoration
- Cut off and replaced the entire front half of the original frame using new neck castings for true 1949 geometry.
- Carefully TIG welded the frame, then painstakingly applied silicon bronze over the welds so they matched the look of old gas welds.
- Collected and restored as many original ’49 parts as possible, undoing decades of modifications and wear.
Engine and Appearance
- Installed a bulletproof S&S Vintage Series 93” engine, then aged the motor cases and any shiny new parts with a scaler to replicate the look of old cast aluminum.
- Modified or disguised bright chrome and modern surfaces to mimic 1949’s unique mix of stainless steel and aged parts.
Finishing Touches for That Period-Correct Look
- Reshaped the front fender and tail for the classic “cut down” hot rod look of the era.
- Chose jet black and antique ivory scallops for paint, topped off with a dangling raccoon tail—a nod to true 40’s and 50’s custom style.
Brian Klock: Blending Custom Style With Authentic Roots
Brian took on a rough, ex-chopper frame he found online—a far cry from showroom condition—and set about transforming it into a tribute that would make his father proud.
Mechanical and Sourcing Work
- Heavily reworked a hacked-up frame with rusted square tubing and a welded neck.
- Sought help from Chris and experts like Greg Lou for help sourcing and restoring rare 1961 parts—including a tin type primary and an new original headstock.
- Tore down the brand new S&S engine to adjust finishes, replaced gaskets, and even remade the oil pump after a sneaky assembly mistake.
Custom Finishes and Family Symbols
- Painted the frame “birch white,” matching the rare color scheme from his dad’s photo.
- Miniaturized ’61-style graphics onto Lowbrow Customs 45” tanks, getting help from friends and old photos for accuracy.
- Dwayne Ballard stitched a classic seat and tank panel.
- Four blue stars were added to the battery box—a hidden symbol that ties back to his family’s love of the Cowboys, riding alongside his brothers in spirit.
Personal Parts Sourcing Challenges
Even the smallest details brought hurdles—like hunting down parts that have long been out of production, then fixing or “making right” pieces that showed up damaged. When every detail matters, patience becomes part of the build.
The Battery and Ignition Secret: Hiding Modern Under Vintage
Building for looks and performance isn’t easy when you want everything to feel period-correct. For spark, the S&S ignition required a modern coil—which looks nothing like a 1949 part. Chris and the team found a clever fix:
- Used a Bates battery box styled exactly like an old six-volt battery.
- Hid a modern anti-gravity lithium battery inside, with the removable top hiding a foam-padded space that’s perfect for the modern coil.
- Routed dummy coil wires to keep up the illusion, while running the real spark through modern gear inside the box.
If you want to see what this trick looks like, check the video above or look up build details on the S&S Vintage Tour page.
More Than Just Bikes: Teamwork, Teaching, and Community
Customs like these aren’t built in a vacuum—they’re a team effort from wrench-turners to storytellers.
Building With and Teaching the Next Generation
Chris didn’t just build alone. With team members like:
- Danny (“our motor witch”)—deep in both motors
- Ian, Aaron, Dave, Todd, Ryan, and Shelton—each hands-on during long garage nights
Chris turned the restoration into a history lesson, handing each person the chance to make one memorable cut on the rare ’49 frame. For many, it was a once-in-a-lifetime moment, and those moments shaped both the bike and the bonds of everyone involved.
Brian and Chris: Friendly Rivalry Turned Collaboration
When Chris moved to South Dakota, these two found themselves neighbors, turning what could have been competition into a creative blend of experience and skill.
“We challenge each other because we’ve both been doing this for years. But we respect the roots, and we push to build—not just assemble—bikes.”
This spirit brought back the camaraderie and shared knowledge that make custom building rewarding, long after the last wrench is turned.
Why They Said Yes: Motivation and Meaning
Building these bikes wasn’t just another job.
“For me, it was a tribute to my dad. For Chris, it was about giving back to the industry and teaching new builders.”
– Brian Klock
“This was a leadership moment for me, but also a shot to tell our story and pass it on.”
– Chris Callen
For both, the chance to work side by side, to honor family, and to set an example for the next generation outweighed every long hour in the shop.
What Makes Each Bike Special?
Chris Callen’s 1949 Panhead Replica
Signature features:
- Stock-style frame precision restored with period-correct welds
- S&S 93” engine perfectly aged to look authentic—and keep up on the road
- Understated paint and trim—no showboating, just pure old-school cool
- Handled so perfectly it could blend into any AMCA lineup
Brian Klock’s “RK’s 61” Panhead Custom
Signature features:
- Immaculate “stance”—low, tough, unmistakable silhouette
- Fat front end, small “invader” wheels for a bold look
- Custom paint and tiny handlebars channel classic bar-hopper attitude
- Four blue stars and birch white paint tell a family story few customs can match
Lessons for Future Builders
Every person involved in these builds walked away with new skills, stories, and the same advice for future vintage motorcycle enthusiasts:
Tell a story through your build—don’t just make something shiny. Build something with real character and personal meaning.
Push beyond your comfort zone. Sometimes the best custom work comes when you surprise even yourself.
Share what you learn. Teach others. Become not only a builder, but a mentor and member of a bigger community.
If you want to dig deeper into the process or see the other featured bikes, check out the S&S Vintage Tour collection, Chris’s broader work at Cycle Source Magazine, or Brian’s shop at Klock Werks.
More Than Metal: Why This Matters
The magic of these builds isn’t just in the polish or the engines—it’s in the stories and friendships forged along the way. As more builders look back at history and look forward to new ways of creating, these P-Series Panheads stand as proof that custom motorcycles, like good stories, are best when shared, remembered, and re-imagined.
Feel inspired to start your own build? Remember what Brian and Chris say: “Whatever you do, make it yours. And never forget—every part and every ride is part of your story.”
