How to build a Street Fighter frame for Evo 120c.i.
 

Customer wants a softail frame that looks like a street fighter frame. I bend the tubing and place it in the jig to give the customer an idea what the cradle will look like. Customer likes the stance so away we go.


http://i865.photobucket.com/albums/a...e/IMAG0078.jpg


With the wheels in place it is easier to see what the bike will look like when it is finished.

http://i865.photobucket.com/albums/a...e/IMAG0080.jpg


Now we need a swingarm pivot tube machined out to accept stock hairy swingarm bearings. On this frame I am trying to keep the weight down so every part I make is designed to be as light as possible without sacrificing strength.

http://i865.photobucket.com/albums/a...e/IMAG0093.jpg

No seat tube on this frame so the rear motor mount and tranny plate will be on a
strong base and post. Rear motor mount is custom hand tortured (plasma, grinder and vertical mill). I even machined to upright tube so it would be at the right height to the thou-ish.

http://i865.photobucket.com/albums/a...e/IMAG0091.jpg


Front motor mount mount is hand carved with plasma and grinder to give it that
custom look. Holes are drilled with center drill then real drill.

http://i865.photobucket.com/albums/a...e/IMAG0092.jpg

More pics to come. Today is swingarm day.

If you are going to add comments please include a picture of a hot chick. Thanks.

Nice! Keep us posted as this progresses..

http://1.bp.blogspot.com/_KtfcVCGY3-...40/ZIPPPPP.jpg

looks really cool.....

That's a good start. Keep the pictures coming.

Swingarm day
 

http://i865.photobucket.com/albums/a...e/IMAG0095.jpg


I wanted to make axle plates that were slightly different than the ones usually seen on custom bikes. I wanted more of a utilitarian look, kind of square and strong looking.

I first make a sketch then I rough one out of foam to see if the customer will like my concept.

Foam rules, you can sand it, shape it, carve it, paint it to look like the real thing (almost).

I`ve used this foam to make custom gas tank concepts as well. That way the customer can see what the finished tank will look like before I make the metal version. This avoids any confusion.

http://i865.photobucket.com/albums/a...e/IMAG0106.jpg

Here is the axle plate mocked up on the axle shaft simulator.
Foam is not that strong so the duct tape acts like a fiber web that multiplies it`s strength.

http://i865.photobucket.com/albums/a...e/IMAG0099.jpg

This gives you an idea what the swing arm will look like when it is finished.

The tubes are held in place with duct tape plus whatever stuff I could find in the shop that worked out to around the right height.

http://i865.photobucket.com/albums/a...e/IMAG0101.jpg

Here you can see the tool I invented for fabricating, it holds parts where you need to hold them. The end is a vice-grip (worlds most useful tool) and the other
parts are ball joints that can be tightened once your part is in position.

I basically took the idea from a similar tool used in soldering electronic parts together and made it much bigger and a lot stronger. I use it all of the time.

That`s it for today, more to follow tomorrow.

Thanks for the pic.
 

Half-Fast: Thanks for the pic!

not to kean on the look , but keep it coming... love seeing the fab work...cool tool as well

frame jig base
 

The base of this frame jig is a cast iron layout plate that was once used to check machined parts to see if they were within specifications.

http://i865.photobucket.com/albums/a...e/IMAG0110.jpg

The ribbing underneath helps to keep this base as flat as possible.

The casting is machined after to ensure it is perfectly flat.

This one was made by the Rutherford Machinery Div in New York, probably around the 1940`s

http://i865.photobucket.com/albums/a...e/IMAG0109.jpg

The cast iron base weighs about 600lbs, the whole jig is probably close to around 1000lbs with all the stuff on top and on the shelf below.

I used an old parts dolly with heavy duty wheels as the lower frame so the jig could be moved around.

more progress
 

http://i865.photobucket.com/albums/a...e/IMAG0112.jpg

Square aluminum tubing has two holes in it, one for the shock at rest and one for shock at full travel. Here I am setting the shock height so I can make the shock mount for the swing arm at right height.

My Jig-Mate tool holds the square tubing at the height I want, so that the shocks ride parallel to the frame and they are up as high as possible while maintaining clearance to get at the tranny nuts.

http://i865.photobucket.com/albums/a...e/IMAG0113.jpg

http://i865.photobucket.com/albums/a...e/IMAG0114.jpg

more progress 2
 

Here I am grinding the fit of the shock mount tube to the swing arm tube.

http://i865.photobucket.com/albums/a...e/IMAG0115.jpg

At the same time I have also started another frame, a symmetrical rigid for a 200mm tire, single down tube, big chopper specs.

http://i865.photobucket.com/albums/a...e/IMAG0118.jpg

Now it is time to make the shock mount, first the raw material is cut to size:

http://i865.photobucket.com/albums/a...e/IMAG0125.jpg

more progress 3
 

Then machined, drilled and tapped.

http://i865.photobucket.com/albums/a...e/IMAG0126.jpg

http://i865.photobucket.com/albums/a...e/IMAG0128.jpg

http://i865.photobucket.com/albums/a...e/IMAG0130.jpg

Then the hole is drilled into the shock mount tube to accept the shock mount:
http://i865.photobucket.com/albums/a...e/IMAG0132.jpg

more progress 4
 

The shock mount is welded to the shock tube and the bottom of the shock tube is closed to strengthen the assembly.

http://i865.photobucket.com/albums/a...e/IMAG0133.jpg

Using the Jig-Mate tool again the shock tube is carefully tacked to the swing arm pivoting shaft so it is square and properly aligned.

Shock tube welded in place:
http://i865.photobucket.com/albums/a...e/IMAG0135.jpg

Now to make the axle plates, first the raw material is cut:
http://i865.photobucket.com/albums/a...e/IMAG0136.jpg

Then the axle slot is machined:

http://i865.photobucket.com/albums/a...e/IMAG0137.jpg

Starting to take shape:

http://i865.photobucket.com/albums/a...e/IMAG0140.jpg

Radius is cut and steel cleaned up on axle plate:
http://i865.photobucket.com/albums/a...e/IMAG0141.jpg

keep it comin, this is bad ass

axle plates
 

OK, went in this morning, the axle base plate was slightly too wide so cut it down to the proper size and fixed the radius so it was perfect.http://i865.photobucket.com/albums/a...e/IMAG0148.jpg

Now it was time to add the other parts so it looks better and is stronger as well.

First is the two solid parts that the tubes slide into:

http://i865.photobucket.com/albums/a...e/IMAG0145.jpg

Then the final small plates are added:

http://i865.photobucket.com/albums/a...e/IMAG0151.jpg

The the exterior welds are cleaned to make it look like a real motorcycle part:

http://i865.photobucket.com/albums/a...e/IMAG0152.jpg

Looks way better than the foam one!
http://i865.photobucket.com/albums/a...e/IMAG0168.jpg

http://i865.photobucket.com/albums/a...e/IMAG0167.jpg

building the swingarm
 

http://i865.photobucket.com/albums/a...e/IMAG0180.jpg

In this picture I am using welding wire to determine the path of the tubing.