MY 79 CHOPPER BUILD THREAD

[phil240]

Over the years I have learned a bit and started off little by little making parts. As you guys know I bend tube for the brat kits and make electronics boxes for the barebones harness kits. I've become more confident in my skills and welding ability. I am by no means a professional welder. But last summer I picked up a clean low mile 79 and decided this was going to be the donor bike.

So with a good solid base to start and a very knowledgeable friend to help me out the build began.

Below is how the bike looked when I first took it home.

 

[phil240]

I knew I was going to need a solid table and also a frame jig. So I went and made my own table. It's a fixture table, welding table and can be used as a frame jig.

This is the table being built and helping me work on my welding a little more. I used my Langmuire plasma table to cut the top. I'm limited to just under 2x2 sheets to cut. And I played with design on Onshape to help with the cad.

 

[phil240]

I got the bike on the table and started to break it down. I stopped after this and bought the neck and axle plates from chop source so I could then go and make the frame jig to attach to the table.

 

[phil240]

Next up I finished breaking it down and set up the frame jig. I made sure everything was square and level. Then I set it up in the jig and checked again for square and level as I set it in the jig.

 

[phil240]

At about this point is when I started flooding the classified section here with all the stock parts for sale. Which I do still have some parts available (tank, fenders, exhaust).

I'll post some more of the updates in the morning.

 

[phil240]

Next was tume to brace it up and cut.

After it was cut I went back to my cad program to design my own axle plate. I went off of a set of common plates to get the angle right for the tubes. After I found a set I was happy with I bent up some tube and set up the hardtail.

 

[phil240]

I went through a couple different axle plate designs and finally was happy with one. I'm a little past this point now but don't want to give away the rear design yet. So I'm stopping this here. But I will let you know took the laser to measure and everything is square. I'll be working on things through the month and will post some updates soon.

 

[phil240]

Has anyone played around with building their own vibratory tumbler?

I'm thinking of making one large enough to do the wheels, but with 3 sections that way I can go from aggressive to a fine media.

Was thinking along the lines of this one https://laserbros.shop/products/tumbler-kit
Was going for that style tub, just modified a bit to fit the wheels and have 3 sections. Then suspended to a frame vis trampoline springs and use a concrete vibratory motor.

Any input or experience?

 

[phil240]

Tank arrived, went with a classic deep tunnel via LowBrow Customs
https://www.lowbrowcustoms.com/coll...riginal-p-nut-deep-tunnel-gas-tank-1-8-gallon

Fender will be made from an old Ford fender.

I've also been sitting on an older Lapera solo seat with a nice tuck and roll design.

I'm on vacation this next upcoming week so hope to make some more progress.

 

[phil240]

Just an idea of the look/lines I'm pulling from.

 

[phil240]

A little more progress
The fender is tac'd on and started seat

Hopefully have time to finish seat and mount the tank this week

 

[phil240]

Just an update

Tank seat and fender are all tac'd into place and set

Working on
electronics box
Floor boards
Foot controls
Exhaust
Handlebars
Wiring

Hopefully I'll be done by june

 

[phil240]

 

[phil240]

Still not 100% on what I'm doing battery box and electronics box wise. I'm trying a couple different things. Idea one of a horseshoe style is already in the trash. Currently thinking of doing a separate battery box and electronics box. Still developing the electronics, but went with a windowed battery box for the 8 cell lithium ion. Currently in the cardboard design phase.