Revised Design: Fat Boy 900 - Made in the USA

[ asked GROK to lower the manufacturing cost of an HD "Fat Boy" It came up with a design that would retail for less that 15k.

Here’s how we adjust the spec from the earlier version:

Engine: Leaner and Meaner

• Stick with the 900 cc Revolution Max V-twin: Keep it at ~65 hp and ~70 lb-ft torque. It’s already in Harley’s U.S. production pipeline (used in the Nightster), so no new tooling is needed. Detune it slightly for simplicity—single cam, basic fuel injection, no frills.
• U.S. Sourcing: Source castings and components domestically to avoid import tariffs, but use cheaper alloys where possible.
• Cost Adjustment: U.S. labor adds ~$150-$200 to engine assembly. Total engine cost rises from ~$2,500 to $2,700.

Frame and Suspension: Bare Bones

• Simplified Softail Frame: Same lightweight steel design, but skip any secondary welding passes or aesthetic flourishes. Powder-coat it black in-house at York.
• Basic Suspension: Conventional forks and a non-adjustable rear monoshock, assembled with off-the-shelf components from U.S. suppliers like Showa’s American plants.
• Cost Adjustment: Labor-intensive frame welding and finishing adds ~$100-$200. Total frame/suspension cost: ~$1,800 (up from $1,600).

Wheels and Tires: Iconic on a Budget

• 17-inch Cast Wheels: Cast in the U.S. (e.g., via Alcoa or similar), using a simpler mold to cut machining time. Matte black finish, no chrome.
• Narrower Tires: 130 mm front, 200 mm rear, sourced from domestic Goodyear or Dunlop plants to reduce shipping.
• Cost Adjustment: Domestic casting and labor add ~$100-$150. Total cost: ~$1,100 (up from $1,000).

Brakes and Electronics: Minimalist Approach

• Single Disc Brakes: 300 mm front, 292 mm rear, with basic calipers from a U.S. supplier like Brembo’s American division. No ABS.
• Bare-Bones Electronics: Analog gauges, basic wiring harness, no rider aids. Assemble in-house to avoid outsourcing markups.
• Cost Adjustment: Labor adds ~$50-$100. Total cost: ~$1,300 (up from $1,200).

Styling and Finish: Raw and Rugged

• Single Matte Black Finish: Painted in Pennsylvania with minimal prep work. No chrome beyond the headlamp bezel.
• Basic Seat: Single-piece vinyl, stitched locally with no premium padding.
• Cost Adjustment: U.S. labor for painting and assembly adds ~$50-$100. Total cost: ~$600 (up from $500).

Production and Overhead

• York Facility: Leverage existing Fat Boy production lines, but streamline the process—fewer quality checks, standardized parts, no customization options.
• Labor Costs: At ~25 hours per bike and $30/hour average (including benefits), that’s $750 in direct labor, plus $250 in overhead (facility, utilities). Total per-unit production: ~$1,000 higher than Thailand.
• Economies of Scale: Assume a modest run of 5,000 units/year to spread fixed costs.

Revised Cost Breakdown

• Engine: $2,700
• Frame/Suspension: $1,800
• Wheels/Tires: $1,100
• Brakes/Electronics: $1,300
• Styling/Finish: $600
• Production Labor & Overhead: $1,000
• Subtotal: $8,500
• Dealer Margin (~20%): $1,700
• Profit Margin (~15%): $1,275
• Total MSRP: $13,475

Price Adjustment

We’ve landed at $13,475—over the $12,000 target by $1,475. To hit $11,999:

• Cut Engine Size: Drop to an 883 cc Evolution V-twin (used in the old Iron 883, already U.S.-made) instead of the Revolution Max. Saves ~$500 by using a legacy engine with existing tooling. New engine cost: $2,200.
• Cheaper Tires: Source budget-tier tires (e.g., Shinko or Kenda), saving ~$200. New wheels/tires cost: $900.
• Tighter Margins: Reduce dealer margin to 18% ($1,440) and profit to 12% ($960).

Adjusted Totals

• Engine: $2,200
• Frame/Suspension: $1,800
• Wheels/Tires: $900
• Brakes/Electronics: $1,300
• Styling/Finish: $600
• Production: $1,000
• Subtotal: $7,800
• Dealer Margin: $1,440
• Profit: $960
• New MSRP: $12,200

With ruthless cost-cutting, we’re still $200 over. Harley could:

• Eat the $200 as a loss leader to hit $11,999, banking on volume sales.
• Market it at $12,199 as “close enough” to the target.

Final U.S.-Built Fat Boy 883

• Engine: 883 cc Evolution V-twin, air-cooled, ~50 hp, ~55 lb-ft torque
• Weight: ~590 lbs
• Wheels: 17-inch cast aluminum, 130 mm front / 200 mm rear budget tires
• Brakes: Single disc front and rear, no ABS
• Top Speed: ~105 mph
• Fuel Economy: ~50 mpg
• MSRP: $11,999 (with Harley subsidizing the last $200) or $12,199

Trade-Offs and Appeal

This U.S.-built Fat Boy 883 is a spartan take on the classic—less power (50 hp vs. 94 hp of the 114), no tech, and a raw finish. It’s still got the disc wheels and Softail stance, but it’s a bare-knuckle ride for purists or newbies. Built in Pennsylvania, it could carry a “Made in the USA” badge, appealing to patriotic buyers despite the compromises. It’d slot below the $13,999 Sportster S in Harley’s lineup, targeting riders who’d otherwise buy a used bike or a competitor like the $9,999 Indian Scout Sixty.