Market for Revision Sports athlete is crowded. Most of the established builders in the United States know their way around the venerable platform, and the dizzying array of aftermarket parts. It takes something very special to stand out — like this custom-framed, limited-production special car from Cohn Racers.
The man behind the Florida workshop is Chet Perez, who was born into a family of motorcycle enthusiasts more than 4,000 miles away in Madrid, Spain. His destiny was predetermined from an early age: “When I was 4 years old, I drove a Yamaha PW50. And when I turned seven years old, I started to race Tests”.
Chet was always working on his bikes, so he learned the mechanics while most of the kids were watching. Rugrats. Then, he moved to the US to study and stay for a few years with Apple, until he realized the world of technology was not for him. So he founded Cohn Racers in 2017.
It was a leap into the depths. “You don’t know how difficult it is to open a motorcycle shop until you actually do it. This is why I have so much respect for every other builder in the industry. Fortunately, a turning point came in 2019, when Chet revealed Harley XR1200 Muscle CHEAP.
“It completely went viral on social media because people loved it. Knobby tires, great suspension, great brakes and an American soul. With the V-twin engine really feels in harmony with the rest of the motorcycle. “
As Chet builds more Muscle R bikes, he’s experimenting with improvements. “I started getting into engineering with a friend, Joan Mataro. We have invested in 3D printers, scanners and software.” But the concept for the Muscle R2 remains the same: A Sportster that has real power, brakes and turns, and has an elegant, thoughtful stance.
Using a Peel 3D scanner, Chet and Joan scanned a rubber mounted 1200cc engine from the latest XL Sportster model, along with an OEM frame and a frame from the XR1200. “These scans gave us a ‘grid’ of millions of points. We’ve developed a proprietary frame that looks strong without compromising on comfort and handles turns in a spectacular way. ”
After virtual testing and simulation, Chet and Joan 3D printed several frames from sturdy PLA, with the same angles as the original XR1200. “Josh Lewis, our master welder, did a flawless job in setting up the fixture and creating the first prototype frame. Now we can make as many frames as we want, in any alloy. We are currently offering Grade 5 titanium alloy frames for future MR2 owners. ”
Next was the journey to design a five-piece swingarm that can be welded and adjusted to the customer’s height. SolidWorks software is used to simulate the various forces and David Sanchez’s BottPower provided technical assistance.
“We also had a current Aprilia engineer test and simulate our final product,” says Chet. “This is one of my favorite parts on the bike, because I love the hollow X on the inside of the swingarm. However, it’s hard to appreciate with the rear wheel! ”
Cohn racers have been using Öhlins for suspension since day one, and for the Muscle R2, they helped choose the best FGRT fork and rear suspension setup to suit every MR2 owner. “We also designed a trio of clamps, machined in CNC aluminum, with just the right offset for mounting the headlights and speedometer,” says Chet. “Being able to model anything in CAD allows you to work in advance.”
Brembo-based brakes are more complex. “I couldn’t find any disc brakes on the market that would fit the bike, so with a piece of paper and a compass, we started experimenting with different models and they I came up with a really unique design. “We used a 330mm floating disc up front and a solid 260mm version for the rear.”
As for the wheels, the team used Harley axles with a custom setup to fit the 18-inch rims – 6 inches wide at the rear and 3.5 at the front. “It gives the bike a flat feel, which was the whole intention of the early XR models from Harley Davison,” says Chet.
“There is a wide choice of suitable tyres, but for some reason customers continue to use dual sport tyres. They’re super soft and have good grip, but we’re excited to build the MR2 with street tires to push its true limits soon.”
The air-cooled Evolution V-Twin engine now has more than 100 hp on 93 octane gas, but Cohn Racer mods don’t compromise on reliability. Aside from the ECU trick, the biggest change is the downdraft intake system that uses a new manifold: it’s CNC cut from a block of aluminum with a 6-axis machine. Two large ducts catch more air than exhaust, and at the other end, the drained gases escape through a full 2-in-2 titanium exhaust. It is finished with an Akrapovič titanium silencer.
Less obvious is a small oil cooler that is forcefully poured into the original oil tank under the saddle, ensuring an ample (and cool) supply. Chet has also kept the original battery setup—“opening the door for people who don’t want to depend on lithium batteries.” The fuel is contained in a tank handcrafted from 2mm aluminum sheet that has been laser cut, bent and welded together.
Carbon weave is everywhere, and beautifully made. “Anton, our carbon fiber guy, worked for the F1 team Scuderia Toro Rosso and Koenigsegg in Sweden,” revealed Chet. “MR2 has more than 20 parts that use pre-impregnated and autoclave carbon fiber.”
“This is one of the most expensive processes to produce composite parts, but it ensures the perfect resin content per strand — and makes the image face distinctive. Paint work is something we offer in collaboration with many artists and can mix exposed carbon with truly exceptional designs. ”
The same care has gone into the cockpit experience. The specially designed multifunction display shows RPM in analog format and other digital information. And the logo on the carbon fiber case is cast in 24k gold from the wax mold of a master jeweler. (“He polishes the piece with several compounds for maximum shine.”)
Custom made aluminum handlebars, with internal cables and control switches that light up blue for easy nighttime operation. The legally required lighting system is discreetly integrated, with the rear fender using only two sections to house all the necessary lighting components as well as the license plate holder.
The paintwork isn’t the only aspect of this Harley that can be modified: every customer can opt for leather upholstery, too. “We usually get the leather from Scotland, but this will depend on the client’s vision,” says Chet. “The leather is carefully curated by our artisans. It defines the manual process. And if you want the MR2 to better suit your taste, Chet is a pleasure to talk to.
“We also tailor and set up every bike for each customer,” says Chet. “We tweak things like ride height, suspension stiffness and other small details to make the rider as comfortable as possible.”
In addition, Chet is also working on his next business project, which will have four wheels instead of two. “We are going to reveal an incredible car we have developed this year,” he revealed. “So we are looking for investors with the same passion as us, to continue to grow in this new phase.”
If you’re drooling at this point, you’re probably not alone. The first Muscle R series was in great demand and one customer sold it at a profit. Cohn Racers has now begun building the first batch of the MR2, with nine pre-orders already on the charts and limited production of 99 pieces worldwide. Prices will start at $45,100 but will likely increase as demand picks up.
A matching Cohn Racers bike and car parked together sounds like a dream garage to us. Interested parties, line up.
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