The Chopper Compendium

I did quite a detailed build report on my frame jig on the old forum and I have made a few modifications as a result of lessons learned fabricating a number of frames on it...if you guys are interested I'll re-post the build here along with the updates and then maybe post some plans in the downloads section..... let me know if you're interested.........

Maz xx

now, how can you even ask a question like that? of COURSE we're interested! do it, do it.

( i just love the dancing banana )

-dan

Well now how can I refuse such a request from the Lord of the Forum

And yeah, that dancing banana is well cool

Maz xx

always intrested in new ideas

Maz, i will be going by your frame jig build when i get started building my proper jig. All your ideas will be very helpful, planning on getting the materials for it through the winter more or less.

Ok so here's the story of my universal frame jig. It was designed from the outset to fit onto my bike table. A couple of reasons for this, firstly this would allow me to raise or lower the whole thing for ease of measuring and welding etc and secondly the table gives it more stability and rigidity, both of which are pretty essential in a frame jig.

Unlike most of the frame jig plans available on-line, mine is intended to be used for metrics and HDs alike. Therefore it had to be completely universal.....

I used 50mm x 50mm x 3mm steel box section as it fits onto the table, but if you are planning to copy it and use it free standing then use at least 50mm x 75mm for the main rails or they might bend under the weight - especially when you put the motor in The location cones and neck pivot boss were machined from solid steel bar stock I originally used 16mm threaded rod for the stem but it flexed under welding so I later changed it to 25mm (1 inch)

To make the jig universal I designed a moving "saddle" which can take an original frame so I can measure up all the mounts to make up a motor mount jig.... This pic shows the basic jig layout before any welding...

More later guys

Maz xx

i found my 3/4 inch rod for the neck was flexing too im also stepping up to a 1 inch rod

Sometimes what you think will be strong enough takes all the force just fine until you start welding and then as the weld cools it just pulls that little bit extra......there's no substitute for using a larger rod..... I just know I'm gonna regret saying that

Maz xx

lol a large rod isnt everything its how u use it

curt wrote:lol a large rod isnt everything its how u use it

oh so very true........

Maz xx