Road Rally Puzzles

Metal magician keeps Harley-Davidsons on the road

Marv Knudtson has never ridden a Harley-Davidson motorcycle, but he has rebuilt the innards of hundreds of Harleys and other bikes to get them back on the road.

To someone as non-mechanical as I am, Knudtson performs magic. Magic in metal. He's a machinist who can bore, cut, weld or otherwise make metal take whatever shape he conjures up in the shop behind his house in south Rapid City.

He doesn't just fix motorcycle parts. He designs and builds new parts. He's creative. "He'll just take it out of a hunk of iron, just make it," says Lyle Robinson, a motorcycle mechanic who has taken work to Knudtson.

Knudtson once fixed an old Harley "45" engine with a piston ring for a Briggs and Stratton lawnmower.

Knudtson works on Harleys, new and old, plus Japanese bikes and snowmobiles.

And it's not just what he does, but how he goes about it.

Knudtson, 78, is gentle, good-humored and humble.

"There are other guys that could do this but probably don't want to," he said.

But the bikers who show up at his shop with broken Harleys are certainly grateful when they're able to ride away.

Bikers from all over the country who know Knudtson have helped drop by his shop to say howdy.

Knudtson explains that on many old Harley engines, the bronze seats for the valves wear out. No problem for Marv. He bores out the worn seat, makes a new seat of cast iron, and drives it into the head.

Newer Harleys don't have a lot of the problems old Harleys had, but a lot of people who buy new Harleys want more power.

So Marv bores out cylinders for individuals as well as for Black Hills Harley-Davidson. He also does machining work for Black Hills Power Sports, Rice Honda, Nostalgia Cycles and Black Hawk Custom V-Twin.

Marv performs his magic with a metal lathe, two welders, two presses, and two mills in his shop. He built the larger of the two presses himself.

A press, he explained patiently to me, is a machine that presses metal parts together - or apart. A mill is used to cut or trim metal.

He makes his own tools for special jobs.

His shop is organized and orderly. Tools hang on the walls. The floor is spotless.

Drawers contain various drills and grinders, micrometers (which he uses to measure parts as he "roughs them out," and dial bore gauges for finer work.

He shows us one gauge that measures in the tenths of a thousandth of an inch.

My sophistication with things mechanical has sometimes devolved to the level of just getting a bigger hammer (with disastrous results to a bar grip on a Suzuki DR 650.

Road Rally Puzzles - News


Metal magician keeps Harley-Davidsons on the road

And he plans to continue working in his shop, solving problems and puzzles in metal. "I really enjoy it out here, doing things, making tooling," Marv said. "If I didn't have this work out here, I'd go nuts." So he'll still get visits from a variety of



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Road Rally Puzzles - Bookshelf

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