Busted Rubber - The Unwanted Child- Build

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Curved Girder Forks

Build up method out of steel for trees. Reuse the stock neck shaft and weld into new lower tree.

I decided to notch the seat bar and tilt it forward. Will help with the seat construction.

I cut the mid controls out the stock frame. Welded the solid and made bars for them to mount to frame.

This will save some time not having to build them.

A few more bars and ready for motor mounts.

Should have it done and welded off the frame jig tomorrow.

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Rear motor mounts done.

Welded.

Off the jig and tire fitted.

[hansgoudzwaard]

This bike needs wheelie bars to balance out the front end.

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he he he?

Ever seen a sport bike with that long a chopper front end? Under 3 ft tall in total and 9ft long when done?

I did not get as far as I would have liked tonight.

Started the finish welding by pulling the frame off motor and welding and joints I could not get with motor in.

Finished the motor mounts up.

1 guy can just pick the frame off the motor.

You need to let the frame cool all the way to weld any gussets in so today set about reinforcing the rear axle plates. I left a gap when I welded tubes to the plates to allow for this gusset.

Got most of the neck gussets cut will have to weld them in tomorrow to finish the frame.It will need the neck gussets with this rake for sure.

[krymis]

looks good man keep up the good work

[curt]

cant wait to see it with the front end on it gonna be crazy long I like

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Thanks

I got the motor back in the frame.

I got the neck gusseted and welded with the gussets on the outsides of the tubes and no welds inside to minimize a stress fracture from a pinch point from a weld there.

I got the rear axle spacers done.

Just got to make the mount for the brake stay bar and controls done. Will do that tomorrow.

Got started on rough scetch of front end. Will be ale to get real life measurements for it when the stay bar is done and can put bike on ground to begin the front end build. By rough drawing the front forks will be a 60 degree angle.

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Made the brake stay bar with 3/4 tube .120 wall and a slight bend to match frame a bit.

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I welded gussets on rear tubes to prevent fracture there.

Started layout for front end by placing wheel where it will be at trail.

Cut the lower tree of neck shaft and turned it down to weld in new lower tree.

[Jeff L]

I was waiting to see where you'd put the Foot Controls.They flow nice with the fender Lines.I know you're trying to use whatever Parts you can off the Bike, but a front End that long is just gonna scream for a skinny Tire.... JMO....The Chop DOES look good though Brother.

[hansgoudzwaard]

TREXTOOTHPICK

WHEELIESNIP.JPG (84.41 KiB) Viewed 9800 times

Wheelie Bars. Attention Getters.

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Bike looks killer with the wheelie bars!

Thanks.

I finalized the prints for the girder.

Turned the stock neck shaft between centers untill the old lower tree was gone and left a 30 mm shaft.

Turned a spacer to bring lower tree down under neck.

I cut the trees to rough shape.

Fly cut the square and equal distances to the print.

Drilled the bottom tree to 30 mm with drill bit.

The upper was 28 mm so, drilled tree with 1 in bit and milled out with rotary table to .005 oversize.

Now have the foundation to use build up method to produce the trees.

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I decided I wanted the girder narrower so fly cut .5625 off each side of the plates. Will be 8.5 in wide now. 6 and a 1/8in to the inside.

I welded 1in dom tube to the ends of the plate to begin the build up of the trees/yokes.
Then fly cut them even with the plates.

Then milled out the slot for the shock.
Milled so it had round corners not to crack the plates latter.

Then turned sleaves out of steel for the bearings to turn against and to have a guides for my 1/2in bolts.

Welded them in place. The sleaves overlap the plates so the weld grabs all 3 pieces.

Then fly cut them so they were perfect with each other and have smooth surface for bronze bearings.

I am now ready to start machining them into their shapes.

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I was able to get my 5/8ths 12 in bolt to tie the trees together thru the neck shaft.

The 2 12in 1/2 bolts to thread down for girder legs that was still needed and the metric drill bit for the front girder legs front axle connections.

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I got the yokes/trees shaped.

I just cut with grinder the lower yoke/tree then ground it smooth.

I milled out for the clamp bolt.

Drilled a hole oversize for the 7/16ths fine thread bolt.

Cut the slot for the clamp with grinder.

Cut the corners off with grinder on the top yoke/tree and then ground into a shape.