In the world of motorcycle customization, innovation and creativity are key to standing out from the crowd. Sean Jackson, from Competition Distributing, is a mechanical enthusiast and vintage motorcycle aficionado that likes to challenge himself when it comes to his two-wheeled projects. Or any projects for that matter. Sean was about embark on a remarkable journey to create a one-of-a-kind motorcycle blending vintage aesthetics and components with aviation inspired mechanics. We sat down with Sean to get the skinny on this inertia-start Panhead that recently won the Biltwell People’s Champ award, and $10,000, during BornFree 14 weekend. Sean was cool enough to share the story behind his unique creation and the challenges he faced along the way.

I built this bike because I wanted to push my own limits on what I could accomplish,” Sean says. “Building this motorcycle for me was driven by a combination of personal growth, creative expression, and passion. It represents a journey of self-discovery, a desire to push personal limits, and a commitment to merging modern and vintage elements. The end result is not only a show bike but also a functional machine that embodies the vision and can be enjoyed by riding it.”

The project began with the discovery of an inertia starter, a relic from World War IIera aviation, which ignited Sean’s imagination. Intrigued by the idea of incorporating this starter into an antique motorcycle, he set out to bring his vision to life. With the assistance of his friend Kevin, Sean acquired the inertia starter, a beautifully preserved Eclipse aviation starter found on eBay. Despite the seller’s uncertainty about its functionality, Sean was undeterred. The $300 purchase arrived like a precious gift, sparking his excitement akin to Christmas morning.

Fueled by his mechanical passion, Sean wasted no time in testing the inertia starter. As he cranked it by hand, the possibilities for his motorcycle build unfolded. The unique bolt pattern and immense torque of the starter led him to design a robust frame capable of accommodating its power. Departing from the conventional tubular frame, Sean drew inspiration from a shop chair he had seen on Instagram. This flat plate design with reinforced bracing became the basis for his innovative motorcycle frame.

Utilizing modern modeling techniques, Sean meticulously crafted a complete Panhead frame, accounting for every nut and bolt. By raising the axle plates and incorporating a single down tube with single backbone, he ensured a lowslung appearance that exuded the charm of vintage motorcycles. This amalgamation of old and new formed the foundation for the rest of the bike’s design.

To complement the unique frame, Sean carefully selected each component, blending elements from different eras. The frontend, modeled after a 1930s HarleyDavidson hill climber, featured a customized stainless steel trailing link suspension—a rare and sought-after component in the motorcycle world. Paired with Buckhornstyle handlebars and other custom details, the overall aesthetic began to take shape.

Sean’s attention to detail extended to the heart of the motorcycle—the 1948 Panhead engine. Sean undertook a complete rebuild, leaving no part untouched. The weathered cases were expertly welded and machined multiple times to restore their functionality and appearance. Sean designed and 3D-printed a dual carburetor manifold with wraparound velocity stacks, providing a visually striking element to the engine. The resulting motor, dressed to impress, became a fitting centerpiece for the bike.

The final result of Sean’s monthslong endeavor is a visually stunning and mechanically awe-inspiring motorcycle that merges vintage charm with modern craftsmanship. Eschewing unnecessary amenities, the bike exudes a minimalist and clean aesthetic, drawing attention to its unique features. With a lefthand hill hold and internal components that facilitate a suicide clutch, Sean’s design ensures a comfortable and secure riding experience. The absence of a front brake highlights the bike’s clean lines and pays homage to classic designs.

The completion of the motorcycle marked a moment of triumph for Sean. Starting the bike for the first time with the inertia starter was a moment of exhilaration akin to hitting a home run. After seven and a half months of hard work, design challenges, and doubts, he successfully brought his vision to life. Contrary to naysayers, the motorcycle proved to be not only visually captivating but also surprisingly easy and enjoyable to ride, as Sean embarked on a 50-mile journey to qualify for the renowned Born Free show, where he took the top prize as the 2023 Biltwell People’s Champ.

Words: Jordan Mastagni

Photos: Geoff Kowalchuk