The Chopper Compendium

Got a friends chop torn down and ground the frame clean of a bunch of old brackets no longer needed. Moving the engine forward to allow room for a proper jack shaft system. Cut the old cobbled up axle plates out and put the frame in the jig. Ready to make a new set of axle plates and then move the engine make new mounts.

Hope the rest of the welds don't look like that axle plate!
Dusty

I believe it is a Amen Savior frame that at one time had a Harley motor on it. The frame has had a few lives and it looks the last couple owners hacked at the back and the frame mounts to put a couple different jap bike engines in it. You can tell the back have has been redone with the upper rear tubes replaced once.

Every tube I have cut out has been .120 wall tube and welded properly. Just the mounts and axle plates were hacked on by guys garage using the frame with very minimum tools available to insert whatever motor they had.

Got the axle plates made. 1/2 inch plate with 5/16 axle adjuster bolts. Slots are machined .020 oversize from 20 mm to allow for paint.

Got the axle plates welded in. They are square with each other and the jig also distanced apart to reuse the axle shaft. Now can know the engine is inline with the axle plates after making engine new mounts.

Got the motor moved forward in the frame. The front motor mount is done with turned spacers and both cross bars are welded in. The engine is aligned center with the frame jig and axle plates using the center casting on the head for the front of engine and a straight edge along the engine sprocket and the jig edge with a square for the rear of engine. The engine was also checked to be level with the jig using the engine oil pan mating edge. Also the engine sprocket is in a straight line with the axle shaft. Now have a 10 inch space to build a proper jackshaft and battery box. Will have plenty of room to run a cool exhaust also.

Change of plans. We took a Kaw 750 Zephyr he had and made a donor bike out of it. The motor is now been welded in and the cross braces moved. Then pulled off the frame jig. We no longer need a jackshaft on the bike and have a larger more power full engine.

Hand made a rear fender that has 1/4 inch clearance for chain. Added 1/8 inch round bar around the outside edge for strength. Made a sissy bar. Got it all mounted.

Got the seat pan made for a King and Queen seat.

We did a quick seat just for mock up so, forward controls could be built out of imitation alligator vinyl. Then I built a set of forward controls for the bike.

Got the queen seat foot pegs made and mounted.

Did some art work on the cases today. If he approves the designs I get to engrave them. If not wipe the cases clean.

Engravings have been approved. Turned to match design some Heat Sink oil coolers to remove the stock oil cooler. Mounted them on the bike.

Got the engine engravings done. Also had him buy a make your own header V8 kit and we pieced from it to make a set of exhaust pipes for the bike.