Proudly Made in the U.S.A., Boss Hoss Cycles, Inc. is located in Northwest Tennessee. Our manufacturing plant, office and warehouse facilities encompass 22,000 square feet on seven acres at 790 South Main Street in Dyersburg, TN. If youre ever in the area stop in and check us out, whether it is just a quick stop by the showroom featuring cycles and apparel, or a pre-scheduled tour encompassing our entire manufacturing facility. From the size of our facility to the number of dedicated employees on staff, you can see first hand that the Boss Hoss is manufactured in a clean, streamlined facility where its crafters take great pride in the products they produce.
The foundation of every Boss Hoss is the 1.5 inch, 0.95 wall, 4130 chrome-molly tubing and investment cast heat-treated 4130 alloy neck (yoke) that make up the frame. Every cut, bend and weld in the construction of the Boss Hoss frame is done by ANSI/AWS certified welders at our facility. Our Fabrication Department also remanufactures the Ford 7.5 inch differential housing that we utilize on all our trikes. We use new high quality performance axles, ring and pinion gears, pinion flanges, brake assemblies, bearings, races and seals. The only component that is not new is the actual rear-end differential housing itself. Every assembly that we weld is placed in a custom jig fixture designed and built at this facility. This allows us to maintain a high level of control over the quality and integrity of our in-house fabricated components. All metal fabricated frames and components are then painted black. We utilize a powder coating paint system that produces a durable, high quality finish that is superior to conventional liquid paint.
Virtually every major component that is not produced by our staff is custom designed and fabricated by experts in that given field exclusively for the Boss Hoss. All the component parts that are purchased from our suppliers are sub-assembled and tested in our Sub-Assembly Department. The proven components are then stocked for the Final Assemblers.
The Final Assembly Department is where it all comes together. The factory new General Motors engines and custom built proprietary 2-speed semi-automatic transmissions with reverse for the bikes, or in the case of the trikes a modified and remanufactured 4L70E 4-speed overdrive automatic transmission with reverse are mated together. After the union of the engine and transmission, the U.S. Patented Boss Hoss frame is wrapped around the drivetrain assembly by splitting the two piece designed frame. This allows the Boss Hoss to maintain a compact design, which contributes to the bikes amazing light feel off the stand and nimble cornering characteristics. Each unit is built on our multi-station assembly line that allows experienced assemblers to construct and document every stage of the assembly process. No Boss Hoss is complete without being test run to our quality and performance specs.