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Customize IT
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SELF INTRODUCTION: I am a young punk kid that needs some help building himself a chopper!!

I am sorry I only have a hotmail account???

Tell me what I need to do I need help with my girder!!!

PLESE HELP????


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Location: Ohio, USA

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Post by Customize IT » Mon Oct 06, 2014 10:26 am

This is a write up I was allowed to do under the banner of: The Chopper Builders Handbook Facebook page.

I took it as a great honor!

Building a set of links for a Custom front end is not hard and can be done by any one able to mark out distances and operate a drill press and grinder.

We will show how to make a set of Girder links here but the same process can be used to build other types of links like in Springer rockers.

1. Go to the Handbook and use to get what measurements you need for the length of your links. This distance will depend on your bike. Variables like rake of neck, size of front tire and rim used, and distance of the neck from ground vary from bike to bike. That is why no hard measurements can be given for links and other components. You have to measure your bike and use handbook to produce parts like these.

2. It is always a good idea to test drill a scrap piece of metal with several drill bits or end mills. End mills can be used in a drill press. With the links the bushings need to be pressed in so you need to find a final size drill bit or end mill that will produce a .005 undersize hole so the bushings turn on shaft instead of inside your links produced. There is another way these have been done and that is to drill and tap a 1/4-20 threaded hole for a set screw to hold bushing in your links. [Figure 1.]

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3. Cut 4 pieces of material to be made into links with grinder or saw. Then clamp and tack weld the 4 pieces together. [Figure 2.]

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4. Lay out and center punch the holes to distance needed center to center. Making sure your links are flat in a vise either in drill press or lucky enough to have available a mill use a center drill or small drill bit to make a clean mark on your links. [Figure 3.]

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5. Use this to mark a perfect radius on your parts to be cut too later.
[Figure 4.]

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6. Pilot and drill the two holes thru the 4 links to your .005 undersize diameter for your connecting points with trees and girder legs. Then use a grinder or a rotary table on mill to shape the links to the shape you marked. [Figure 5.]

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7. Grind the weld tacks off your links. VERY IMPORTANT do not take out vise after last side is cleaned from weld tacks. You will see why next step.
[Figure 6.]

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8 With the links still in vise but weld ground free now mark how they were position relative to each other when drilled. They as shown with a mark here for T being top and B being bottom set of links. The center punched dots show what faces where mated next to each other. This is done because the holes may not be totally perfect across the hole length but, allows for the links to be closest to the next link to it and gives your bushings a longer life. [Figure 7.]

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9 Using a flap wheel in a grinder smooth each link outside edges down and then either with large drill bit, round file, or counter sink by hand remove all the sharp edges from each part. [Figure 8.]

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10 With a vise press the bushings in the links. [Figure 9.]

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Now you have just build a set of links for your custom chopper front end.
[Figure 10.]

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All the material specs and other need info is in the handbook.

http://www.chopperhandbook.com/

Remember we have a forum if you need help, and the only stupid question is the one not asked as my Grandfather always told me. We care not what type off bike or model you ride. Any are welcome searching for info to make a Custom bike of any type.

http://choppercompendium.com/ccforum/

We also have CDs that show how to build frames and other front ends. With actual prints in them of frames and front ends. You could build a full bike from them no engineering!

http://www.chopperhandbook.com/cd1.htm
MAKE IT YOURS!!!

Altenative Energy Motorcycle
The owner is driven by:
BEER, BOURBON, WEED, & WOMEN

RIDE HARD, RIDE FAST,RIDE LOUD

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