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  #1 (permalink)  
Old 08-02-2009, 08:56 AM
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Custom chopper bicycle in the works...

I just found this forum recently and thought I would post a thread documenting the build process of a chopper bicycle I designed and built during a 6 month period starting in August 2005. I first displayed the finished bike at the Detroit Autorama in March 2006. It has had a few more tweaks since that show. I will condense the build as much as I can, I have plenty of pictures. So for anyone interested, here goes.
First two pictures attached. This is my original, full size line drawing showing what the finished bike pretty much looks like. I started with one of those 2004 Schwinn OCC 20" Stingray chopper bicycles, like the green one shown in the second picture. Since I am about 6'3", I had to make the bike a little larger to fit me. From the center of the rear wheel to the center of the crank was stretched about 10". Head tube is stock length and tilted back at 45 degrees, this is maybe 10 degrees more than stock. Fork length is about 48", stock length is 28". Overall length: about 8'6" or 102". Wheelbase: about 78-7/8". I work in a metal fabrication shop, so I have access to tubing, sheet metal and metal forming equipment. I used 1" and 1-1/2" round tube for the frame, the 1-1/2" matches the head tube and crank tube size. I will post new pictures and updates every few days. Thanks for looking.
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Custom chopper bicycle in the works...-original-line-drawing-1.jpg   Custom chopper bicycle in the works...-original-line-drawing-2.jpg  
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  #2 (permalink)  
Old 08-02-2009, 09:03 AM
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Well, pretty cool I guess, but wheres the motor? Not to bust on you but this is a chopper forum with big boy choppers.

Might be more suited here..
http://www.bikeforums.net/index.php?
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Old 08-03-2009, 03:01 AM
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Well, there must be some interest in this project since there have been nearly 60 views of this thread in the first day it's been up. I see that this is about motorcycles here, but I thought I'd give it a shot since this forum isn't actually called club 'big boy' chopper. I guess I will continue. How about looking at it this way, maybe those Dads out there with a son that's too young right now for a big boy chopper can use this as inspiration to build a chopper bicycle for thier son. I'm a big fan of motorcycle choppers, and shows like 'Biker Build Off' and 'American Chopper' inspired me to build this bike. I'm just not a motorcycle rider.

Continuing. Here are some pictures of the frame in progress. I built a welding fixture to hold the frame as it comes together. Note that I still have to cut away part of the original bottom oval tube on the frame, it's just that with the way I'm putting it together I have to leave certain parts in place until the new pieces are welded on. As you can see, about the only original parts of the frame that will be left are the crank tube, part of the seat tube, parts of the chain guard mounting brackets and the rear section. (The rear section will end up being being redone later, this was the first version.) In the full side view shot, a preview of how it will look with the wheels and tires.
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Custom chopper bicycle in the works...-custom-1-090405.jpg   Custom chopper bicycle in the works...-custom-3-090405.jpg  

Last edited by one-adam-twelve; 08-03-2009 at 03:13 AM..
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Old 08-03-2009, 03:12 AM
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A few weeks later, here is where I was at. The frame is just about finished, for now it is just tacked together. An arbor press was used to form the two curved tubes. We didn't have a tube roller, so I had to fabricate a small fixture to make the forming easier. I will be making a custom 3-speed shifter arm, the shape will resemble an old Hurst shifter.
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Custom chopper bicycle in the works...-custom-4-100205.jpg   Custom chopper bicycle in the works...-custom-5-100205.jpg  
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Old 08-03-2009, 03:32 AM
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Another week later and I finally got the billet triple trees and forks mounted. Had to fabricate custom mounts from 1/4" plate for the front wheel. We didn't have our laser yet so these were made the old fashioned way (with a bandsaw and belt sander). At the time these pics were taken, I still had to trim off the ends of the forks. They will be angle-cut, horizontal with the ground. They will end up being around 4 feet long.
I found the billet trees on Ebay, someone had made several sets just for this application. They are sweet (and very rare). The handle bars shown would eventually be changed to a lower profile set. Overall length of the bike comes in right around 102" (8'6"). I'm planning to fabricate new rear tubes (around the rear tire) from 1" round tube to replace those stock rectangle tubes, I think the design will flow better when the entire frame is made from the round tubing.
The white seat will eventually be replaced by a red one, which would end up being the final color scheme.
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Custom chopper bicycle in the works...-custom-9-100905.jpg  
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File Type: jpg custom 11 100905.jpg (44.0 KB, 148 views)
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Old 08-03-2009, 05:57 PM
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Another week later and installed the crank, pedals and a modified, longer chain. I fabricated shifter brackets and a shifter arm in a shape to resemble the classic Hurst shifter with a real 8-ball threaded onto the top.
Another two weeks and I finished remaking the rear of the frame out of 1" round tube. Much better flow with this design.
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Custom chopper bicycle in the works...-custom-20-102805.jpg   Custom chopper bicycle in the works...-custom-22-102805.jpg  
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Old 08-03-2009, 08:56 PM
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Its cool Rick......be nice
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Old 08-04-2009, 02:42 AM
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Thanks John for the nice comment. Just a few more posts and the finished bike will be revealed.

So, about 3 weeks later and here we are. Fabrication was pretty much finished. Just needed to coordinate with a buddy at work to have the frame tigwelded - then it's time to prime and paint the frame! I found a chrome plater to do both forks and the shifter arm. I have the stock V-handlebars mounted for now, but these would be changed later. The rear brakes and cable are mounted, this would be changed to a disc brake about two weeks later. For now I have the rear brake cable taped to the outside of the frame to simulate the routing to get the right length. In final assembly, it will route through the frame for a cleaner look. Also got the 3-speed shifter cable mounted and working. Also got the kickstand mounted.
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Custom chopper bicycle in the works...-custom-42-112005.jpg   Custom chopper bicycle in the works...-custom-43-112005.jpg  
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Old 08-04-2009, 02:56 AM
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About 2 months later and the priming and painting of the frame was happening. Here are the pictures. First, several coats of gray primer with sanding between layers. Then a few layers of metallic red which would be followed by several coats of clear.
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Custom chopper bicycle in the works...-custom-50-012406.jpg   Custom chopper bicycle in the works...-custom-53-012406.jpg  
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Old 08-04-2009, 03:24 AM
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Quote:
Originally Posted by pushrod243 View Post
Its cool Rick......be nice
I actually was being nice. And I did say pretty cool, just not the ideal venue for this, only trying to help.
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Old 08-04-2009, 07:47 AM
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Looks better chopped. That green thing was f'n ugly. Don't go with the gay white seat. Have someone here make you something (that's how you get some interest here).
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Old 08-04-2009, 09:15 AM
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Nice job. Someone else on this site posted a pic. of a bike where he mounted a small motor and it was very cool.
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Old 08-04-2009, 09:42 AM
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I like it, real cool, I agree with rick that this probably isnt the best for a bicycle topic (board wise) but it is a real cool bike build non the less. I like the way it came out, put an insert with your name and number and you got a buisness. Id buy one.
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Old 08-04-2009, 06:09 PM
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Thanks guys. Yes, the gay white seat didn't last long.

I'm just going to fast forward to how the bike looks today. Over the last couple of years since it was finished some minor tweaks were made. Added the rear disc brake and I picked up a great set of chromed wheels, which really set it off.

Just recently I changed the rear tire to an actual motorcycle tire, which fits nicely on the 4" wide rear rim. The tire is just over 5" wide, which is as wide I could fit without interference from the chain. Since I put this tire on, I have been searching for a fender that will fit and match up well with the tire size. Something that wraps around it closely.

Maybe someone on the forums here can help me out? The tire is an Avon AV59 130/70ZR16. The fender can be rough, a little rusty, whatever. I like the shape of some of the rear fenders on the Martin Bros. bikes, so as long as I have something to start that would be cool.

You can send me a PM or email with the information.

Guys, thanks again for allowing me to post this quick recap of the build of my chopper bike.

Mike
Attached Thumbnails
Custom chopper bicycle in the works...-custom-159-071909.jpg   Custom chopper bicycle in the works...-custom-163-071909.jpg  

Last edited by one-adam-twelve; 08-04-2009 at 06:16 PM..
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Old 08-04-2009, 06:24 PM
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What the heck, two more pics.
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