@CopyCat , words escape me...except maybe *nice job*! As for the weight, the 540lb figure looks an awful lot like a rubbermount weight. I thought all the solid mounts were right around 500-503. The stock Sporty frame is wicked heavy and I think one would be hard pressed to whittle enough away to make a meaningful difference, especially with rear suspension. I put together a rigid Sporty using a Paughco Loop frame. The bike ended up only weighing 425lbs but I've sacrificed rear suspension. There's a hell of a lot of structure at the rear motor mount and swingarm pivot on those stock frames. Your bike is inspiring...in fact, I have a spare Sporty frame in the shed; hmmmm.