Mini Chopper Plans

Designed By Solution Design (Design Images not to be used without written permission) P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated) More info at www.minichopperplans.com

MINI CHOPPER PLANS BY SOLUTION DESIGN (Revision2A Nov6, 05) CLICK HERE TO REGISTER & UPDATE

Frame#2 The Little Tyke (Page 27)

Frame#1 The Little Stretch (Page 6)

Frame#3 The Rat Fink (Page 41)

Frame#4 The Easy Brute (Page 62)

Frame#7 The Low Boy (Page 104)

Most Popular

Frame#8 The High Boy (Page 116)

Frame#6 The Hulk (Page 90)

Frame#5 The Black Widow (Page 74)

COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

1


Need To Know How? Need To Know NOW? Then check out the world’s largest mini chopper resource on the web!

HardCoreMiniChoppers.com Here’s a small sample of the topics you can learn from and participate in: • • • • • • •

Frame Building Engines Clutches/Torque Converters Bodywork / Paint Front ends Electrical Bar Stool Racers & Other Custom Rides

Some of the most knowledgeable builders in the industry call the Hardcore Mini Chopper Forum home….shouldn’t you?

Welcome to Hardcore Mini Choppers COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

2


INTRODUCTION • Research the necessary cost & tools required to start this project. It would be a disappointment to start but never finish. Keep in mind that you could rent or have the more complex work done for you if you do not have the experience or the tools. Get written quotes for material and labor. This will help protect you from being overcharged. Tools Required • Tube bender • Welder, (I use a small Lincoln 135t portable welder) • Drill • Wrenches, sockets, grinder, screwdrivers, hole saw, etc. Where to Begin •

• •

• • •

I started by building the frame, bending the necessary tubes to create the main frame and the handlebars. I used the details I have provided to make these parts. I tack-welded the frame only until I had the complete mini bike built. I wanted to be sure the position of the handlebars; foot pegs and seat fit my nephew. Make sure the engine and clutch are aligned straight with the rear sprocket. This is critical to smooth operation. Make sure the rear tire is also aligned straight. I used a make-shift wooden jig to hold the frame while I measured to ensure the axel bolt was in the right position. I drilled the holes first, then using clamps, positioned them in the right position before tack welding. Do not allow any pre-test runs before the brakes have been added. I have seen a few minor spills that could have been much worse because the bike was ridden without brakes. Have all worked checked by a professional. Good welds are vital to safety! Measure twice - cut once. Be safe!!!!! I miscalculated a few times and had to go back for more tube. I found out that it is a heck of a lot more expensive when you only buy in small quantities. Quite often the cut charge is more than the piece you may have needed.

Use only D.O.M tube. All water pipe, conduit, fencing, etc., have different properties. They also are not a true and perfect diameter. When you bend these using a precision bender, the bends are weak because they do not fit the dies correctly.


3


Disclaimer and Limitation of Liability THE ENTIRE RISK AS TO THE QUALITY AND PERFORMANCE OF MATERIALS, INFORMATION, ACCURACY, ADEQUACY, COMPLETENESS, CURRENTNESS, VALIDITY AND QUALITY OF INFORMATION IS WITH THE USER. IN NO EVENT WILL SOLUTION DESIGN BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE OR CONSEQUENTIAL DAMAGES OR ANY CLAIM ATTRIBUTABLE TO ACCIDENTS, MISHAPS, FIRES, ROLLOVERS, EXPLOSIONS, FAILURES, ERRORS, OMISSIONS, OR OTHER INACCURACIES IN, OR DESTRUCTIVE PROPERTIES OF ANY MATERIALS, MANUALS, INFORMATION ECT READ THE FOLLOWING ENGINES, AND THE EQUIPTMENT THEY DRIVE ARE AND CAN BE VERY DANGEROUS TO OPERATE. THEY ARE ALSO DANGEROUS TO WORK ON. IT IS ASSUMED THAT ALL PERSONS WORKING ON OR WITH THE MATERIALS IN QUESTION ARE CERTIFIED AND QUALIFIED TO WORK ON OR WITH THE REQUIRED TOOLS.


4


Helpful Hints Plan, Plan, Plan - Building on the fly is fun but can be costly! Take the time to understand the project, the materials and the total cost. Measure twice - cut once!!!!!!!!!!!!!!! This is the golden rule!!!!!!!! Good professional welds are important!! Do not compromise safety!!!!! When welding the frame, tack it first!!!! You may want to change the frame to fit your needs and a tack can be easily removed! Build the jig; it is well worth the extra time. It will ensure the frame is straight and accurate Ebay has some great deals!!!!!!!!!!!! Shop around for the best prices! Be sure you have brakes! Resist the temptation of that first ride unless the bike is complete. Take your time!! Do not cut corners!! You will end up with a much better final project Be sure you know how to operate the required tools. If you don’t, seek the assistance of somebody who does. This project can be a great learning tool. Wear all necessary protective clothing when working with grinders, welders, and other power tools. Always wear safety glasses when working with ANY tools.


5

Designed By Solution Design (Design Images not to be used without written permission) P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated) More info at www.minichopperplans.com Frame Bill Of Material Item

Name

Description

1. 2. 3. 4. 5. 6. 7. 8.

Frame D.O.M Steering Neck D.O.M Engine mount plate Axel hangers Front gusset Jack shaft hangers Fender supports Fender mount brackets

See frame B.O.M See frame B.O.M See detail See detail See detail See page See page See page

9. 10. 11. 12. 13. 14. 15. 16. 17.

Front tire mount brackets Front fork tubes Triple Trees Steering Bolt Handle bar risers Handle bars Front tire assembly 16" or 20"

Purchased

Fabrication Req’d

Quantity

Yes Could be either Could be either Could be either Yes Yes Yes Yes

Online links Online links Online links Online links Online links Online links Online links Online links

Could be either Yes Could be either Yes Could be either Could be either Yes

Online links Online links Online links Online links Online links Online links Online links

I used a 5hp Tecumseh See page

Yes Yes

Online links Online links

See page

Yes

Online links

See page

Yes

Online links Online links

Yes Yes Yes Yes

Online links Online links Online links Online links

Front End Bill Of Material See detail See front end B.O.M See detail 3\4- 10nc x 6” long See detail See detail See page

Engine Drive Train Bill of Material 18. 19. 20. 21.

22. 23. 24. 25. 26.

27. 28. 29. 30. 31. 32. 33. 34.

3.5hp - 6h.p side shaft engine Option #1 standard clutch & jack shaft set-up Option #2 belt driven torqueconverter set-up Chain length to suit option 1 or 2

Axel hangers Bearing cages 1" Diameter bearings 1" Diameter live axel with retainers Rear tire size 18.8-8.5-8 for wide tire frame Or 15-6.00-6.00 for medium tire frame Rear Rim 4 bolt Rear disc Rear disc hub Rim Hub Rear sprocket Rear sprocket hub Throttle assembly Front brake lever and cable

Rear Wheel Bill Of Material See page See page See page See page See page

Yes

See page See page See page See page See page See page See page See page

Yes Yes Yes Yes Yes Yes Yes Yes

Online links Online links Online links Online links Online links Online links Online links Online links

See page See page See page See page

Yes Could be either Yes Yes

Online links Online links Online links Online links

Custom Parts to Suit Your Taste 35. 36. 37. 38.

Gas tank Seat Rear fender Kick stand


6


Mini Chopper #1 The Little Stretch MEDIUM TIRE FRAME SERIES

REAR TIRE SIZE 15 X 6.00 –6 FRONT TIRE 16” BICYCLE ENGINE SIZE 2-6.5 HP

Suitable for riders who may want to convert their conventional mini bike into a mini bike chopper .If you have never rode a stretched-out mini bike, you might be better off moving on to the next frame - “The Little Tyke”

NOT SUITABLE FOR BEGINNERS “Riding mini bikes with stretched-out forks requires skill and balance. Learn the basics on a conventional mini bike before graduating to a chopper”


7


Medium Tire Frame Bill Of Material

FRAME B.O.M Detail # 1 2 3 4 5 5a 6 7 8 (3 Required) 9 10

Material 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M

Wall Thickness .083” .083” .083” .083” .083” .083” .083” 083” .083” .083” Note***.120”


Length Required 34.0” 26 3/4” 38.5” 38.5” 12 21/32” 12 21/32” 20 7/16” 18.5” 9.0” 10 3/32” 6 1/4”

8


FRAME DETAIL #1 • •

Tube length 34.0”, Diameter 1.0”, Wall thickness .083” Two notches required


9


FRAME DETAIL #2 • Tube length 26 3/4”, Diameter 1.0”, Wall thickness .083” • Two 90 degree bends required • I like to add a few extra inches to the ends and trim them to length when I tack weld the frame


10


FRAME DETAIL #3 • • •

Tube length 38.5”, Diameter 1.0”, Wall thickness .083” One 75 degree bend with a 15 degree tube notch Bend radii is 3.5”


11


FRAME DETAIL #4 • • • •

Tube length 38.5”, Diameter 1.0”, Wall thickness .083” One 75 degree bend with a 15 degree tube notch This notch is opposite to that of detail #3 (See 3D view for more info) Bend radii is 3.5”


12


FRAME DETAIL #5

• • •

Tube length 12 21/32”, Diameter 1.0”, Wall thickness .083” One notch and minor grinding to match to center frame tube (See 3D View for more info)


13


FRAME DETAIL #5a • •



14



Tube length 20 7/16”, Diameter 1.0”, Wall thickness .083” Two notches required


15


FRAME DETAIL #7 •

Tube length 18.5”, Diameter 1.0”, Wall thickness .083”


16



Tube length 9.0”, Diameter 1.0”, Wall thickness .083” Two notches required 3 of these required for seat & jack shaft mounting


17



Tube length 10 3\32”, Diameter 1.0”, Wall thickness .083” Two notches required


18


FRAME DETAIL #10 •

Tube length 6 1/4”, Diameter 1.0”, Wall thickness .120”

ENGINE MOUNT PLATE • •

Use plate steel 3\16” thick Center your engine and then transfer holes


19


AXEL & FRAME MOUNT PLATE • • • • •

Use 1\4” thick plate steel if making these from scratch The hanger below is a modified hanger that you can buy cheap, just weld a triangle shape extension to the top of the hanger to match the frame angle See the assembly views in the rear for axel and bearing mount info Transfer bearing mount holes to ensure proper pattern These can also be purchased on my website minichopperplans.com


20


FRAME GUSSET •

Use 3\16 “ thick plate steel

•

When your frame is complete and you are happy with the angles and the position of the forks, be sure to add frame gussets. You can use a cardboard template and make a mock gusset and then trace it onto your plate steel.


21


MEDIUM TIRE FRAME JIG

This is the most important step in building your frame, this jig will ensure the frame is assembled straight and accurate


22


Medium Tire Frame Jig Bill Of Material


23


Frame Assembly Information

Clamp or screw axel hangers in position, then tack weld

Weld detail 1, 2 & 10 together to make a sub-assembly

Finish the frame by measuring to be sure the frame details are in their proper position COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

24


Main Starting Point for The Frame 1. Begin by tack welding the lower frame rails, foot rest and rear support. The position of the rear support is dependant on the size of your rear tire. I also use it to hold the rear fender. Only tack weld these pieces !!!!!!!!!!!!!!!!!!!!!!!!!!! You may run into problems and find you would like to move some of the frame parts !!!!!!!!! This set up will be the most important!


25


Medium Tire Frame Side Profile


26



27


Mini Chopper #2 The Little Tyke REAR TIRE SIZE 15 X 6.00 –6 FRONT TIRE 16” BICYCLE ENGINE 2-6.5HP Suitable for young riders and smaller engine sizes (2hp to 6.5hp). One of the benefits of a frame this size is the availability of parts. Most of these parts can be purchased from a go-kart or mini-bike parts supplier. This is a great frame for younger riders because the forks are not as stretched-out as other models.

A GREAT BEGINNER BIKE


28



29



Tube length 34 1\4”, Diameter 1.0”, Wall thickness .083” One notch required


30


FRAME DETAIL #2A & 2B • •

Tube length 14 3\4”, Diameter 1.0”, Wall thickness .083” One notch required per detail


31


FRAME DETAIL #3 & 4 • •

Tube length 53 1\4”, Diameter 1.0”, Wall thickness .083” One notch required per detail


Tube length 9.0”, Diameter 1.0”, Wall thickness .083” Two notches per detail


32



Tube length 9 5\8”, Diameter 1.0”, Wall thickness .083” Notch 2 Places

•

FRAME DETAIL #7 •

Tube length 9 5\8”, Diameter 1.0”, Wall thickness .083”


33


ENGINE MOUNT PLATE DETAIL •

Use 1\8” mild steel plate

FORK DETAILS •

Use 1 1\2” .085” wall tube


34


Little Tyke Rear Profile


35


Little Tyke Frame Dimensions


36


The Little Tyke Jig Bill Of Material


37



38



39



40



• • • • •

Fasten details 3 & 4 into the wooden jig Screw or clamp the axel hangers into position Weld the steering neck, detail #1, detail #2A, detail #2B and detail #7, together then place into the jig Check to make sure all components are straight then tack weld Once complete, remove the frame, weld completely, and then move onto the drive train COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

41


Mini Chopper #3 The Rat Fink WIDE TIRE FRAME SERIES REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9HP

NOT SUITABLE FOR BEGINNERS “Riding mini bikes with stretched-out forks requires skill and balance. Learn the basics on a conventional mini bike before graduating to a chopper”


42


Wide Tire Tube Frame Bill Of Material

FRAME B.O.M Detail # 1W 2W 3W 4W 5W 5aW 6W 7W 8W (3 Required) 9W 10W

Material 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M 1.0”Dia D.O.M

Wall Thickness .083” .083” .083” .083” .083” .083” .083” Note*** .120” .083” .083” Note***.120”


Length Required 38 11/32” 30 11/16” 43.5” 43.5” 17 5/32” 17 5/32” 20 7/16” 23.0” 12.5” 11 1/8” 6 1/4”

43





44


FRAME DETAIL #2 • Tube length 30 11/16 ”, Diameter 1.0”, Wall thickness .083” • Two 90 Degree bends required. I like to add a few extra inches to the ends and trim them to length when I tack weld the frame


45



Tube length 43.5”, Diameter 1.0”, Wall thickness .083” One 75 Degree bend with a 15 degree tube notch, Bend radii is 3.5”


46



Tube length 43.5”, Diameter 1.0”, Wall thickness .083” One 75 Degree bend with a 15 degree tube notch, Bend radii is 3.5” Be sure to notch the tube opposite of detail #3


47


FRAME DETAIL #5

• •



48


FRAME DETAIL #5a • •

Tube length 17 5/32”, Diameter 1.0”, Wall thickness .083” One notch and minor grinding to match to center frame tube

(See 3D View for more info)


49





50


FRAME DETAIL #7 Tube length 23.0”, Diameter 1.0”, Wall thickness .083”


51



Tube length 12.5”, Diameter 1.0”, Wall thickness .083” Two notches required


52





53


FRAME DETAIL #10 Tube length 6 1/4”, Diameter 1”, Wall thickness .120”

ENGINE MOUNT PLATE • •

Use 3\16” thick plate steel Center your engine and then transfer holes


54


AXEL & FRAME MOUNT PLATE • • • • •

Use 1\4” thick plate steel if making these from scratch The hanger below is a modified hanger that you can buy cheap. Just weld a triangle shape extension to the top of the hanger to match the frame angle See the assembly views in the rear for axel and bearing mount info Transfer bearing mount holes to ensure proper pattern These can also be purchased on my website minichopperplans.com


55


FRAME GUSSET •

Use plate steel 3\16 “ thick

When your frame is complete and you are happy with the angles and the position of the forks, be sure to add frame gussets. You can use a cardboard template and make a mock gusset and then trace it onto your plate steel.


56


JIG WIDE TIRE FRAME

This is the most important step in building your frame; this jig will ensure the frame is assembled straight and accurate


57


Wide Tire Frame Jig Bill Of Material


58



59



Clamp or screw axel hangers in position, then tack weld

Weld detail 1, 2 & 10 together to make a sub-assembly

Finish the frame by measuring to be sure the frame details are in their proper position COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

60


Main Starting Point for The Frame Begin by tack welding the lower frame rails, foot rest and rear support. The position of the rear support is dependant on the size of your rear tire. I also use it to hold the rear fender. Only tack weld these pieces !!!!!!!!!!!!!!!!!!!!!!!!!!! You may run into problems and find you would like to move some of the frame parts !!!!!!!!! This set up will be the most important!


61


WIDE TIRE FRAME DIMENSIONS


62


Mini Chopper #4 The Easy Brute WIDE TIRE FRAME SERIES REAR TIRE SIZE 18 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9 HP NOT SUITABLE FOR BEGINNERS “Riding mini bikes with stretched out forks requires skill and balance. Learn the basics on a conventional mini bike before graduating to a chopper”


63



64





65




FRAME DETAIL #3 •

Tube length 12 1\2”, Diameter 1.0” Wall thickness .083”


66







67


FRAME DETAIL #6

• •


Engine Plate Detail •

Use 3\16” thick mild steel plate


68


Frame Profile


69


The Brute Jig


70


• Screw together - Do not nail


71



72



73


• • • • • • •

Load details 3, 4, & 5 into the jig Weld detail #1 to the steering neck outside of the jig Screw or clamp the axel hangers into position Tack weld detail #2 to the axel hangers Tack weld in detail #1 with the steering neck Check to make sure all components are straight, then tack weld Once complete, remove the frame, weld completely and then move onto the drive train COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

74


Mini Chopper #5

The Black Widow WIDE TIRE FRAME SERIES REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9 HP


75



76


Detail #1 • •

For this detail use a 1” Diameter, .083” Wall, D.O.M Tube 37 11/16” long Make two notches as shown below


77


Detail #2 • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube, 34 1/8” long Make (2) 90 degree bends and (2) 50 degree bends as shown below


78


Detail #3 • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube 36 1\8” long Make (2) 90 degree bends and (2) 17 degree bends as shown below


79


Detail #4 & #6 • • •

For this detail use a 1” Diameter .083” Wall D.O.M Tube, 10 3/8” long Make one bend & two notches This detail does not have to be exact. It will hold the jack shaft mounting tabs


80


Detail #5 • •

For this detail use a 1” Diameter .083” Wall D.O.M Tube, 12 1\2” long Make two notches

Engine Mount Plate Detail • •

For the engine mount plate, use a 12” X 7 3\4” plate, 3\16” thick Transfer the holes from the engine to mount in the proper location


81


Detail #7 & Detail #8 • • • •

For this detail use a 1” Diameter .083” Wall D.O.M Tube, 50 1\8” long Make one bend and add two notches to complete A compound notch will be required to fit this tube to the neck Make sure the notch at the steering neck matches the neck tube diameter

•


82


BLACK WIDOW JIG



83


Black Widow Jig Bill Of Material


84



85



86



Clamp or screw axel hangers in position, then tack weld Weld detail 1 & 9 together but measure to make sure it is centered

Use clamps to align the frame and make sure all the frame pieces are square Only tack weld the frame first! You may want to make a change later Measure and Measure! Make sure the frame pieces are in the proper location! Detail #4 & #6 will mount as shown, these will hold the jack shaft


87


Black Widow Frame Side Profile


88


Black Widow Rear Profile


89



90


Mini Chopper #6 The Hulk WIDE TIRE FRAME SERIES REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9 HP


91



92


Detail #1 • • •

For this detail use a 1” Diameter .083” Wall piece of D.O.M tube, 36 1\8” long Notch both ends as shown The 25 degree notch must match the steering neck tube diameter


93


Detail #2 & #3 • •

For this detail use a 1” Diameter .083” Wall D.O.M Tube 36 1\8” long Detail #2 and #3 are the same


94


Detail #4 & #5 • • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube 49 1\8” long Make one bend and add two notches to complete A compound notch will be required to fit this tube to the neck Make sure the notch at the steering neck matches the neck tube diameter


95


Detail #6 & #7 • • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube 10 3/8” long Make one bend & two notches This detail does not have to be exact. It will hold the jack shaft mounting tabs


96


Detail #8 • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube 11 1/16” long Make two notches to match frame


For the engine mount plate use a 12” X 7 3\4” plate 3\16” thick Transfer the holes from the engine to mount in the proper location


97


The HULK JIG



98


The Hulk Bill of Material


99



100



101



Clamp or screw axel hangers in position, then tack weld Weld detail 1 & 9 together but measure to make sure it is centered

Use clamps to align the frame and make sure all the frame pieces are square Only tack weld the frame first! You may want to make small changes later Measure carefully! Make sure the frame pieces are in the proper location! Detail #6 & #7 will mount as shown; these will hold the jack shaft


102


The Hulk Frame Side Profile


103


The Hulk Rear Profile


104


Mini Chopper #7 The Low Boy WIDE TIRE FRAME SERIES REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9 HP


105



106





107


The Low Boy Side Profile


108


The Low Boy Jig


109


• BE SURE TO SCREW THE JIG TOGETHER • DO NOT NAIL • PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT CRACK THE WOOD


110


FRAME DETAIL #2 & #3 • •

Tube length 36.0”, Diameter 1.0”, Wall thickness .083” Two bends required


111


Detail #4 • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube, 11 1/16” long Make two notches to match frame

Detail #5 & #6 • • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube, 10 3/8” long Make one bend & two notches This detail does not have to be exact. It will hold the jack shaft mounting tabs


112


Detail #7 & Detail #8 • • • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube, 44 1\8” long Make one bend and add two notches to complete A compound notch will be required to fit this tube to the neck Make sure the notch at the steering neck matches the neck tube diameter


For the engine mount plate use a 12” X 7 3\4” plate, 3\16” thick Transfer the holes from the engine to mount in the proper location


113



114



115


The Low Boy Side Profile

• • • • • • •

Load details 7, 8, & 3 into the jig Weld detail #1 to the steering neck outside of the jig Screw or clamp the axel hangers into position Tack weld detail #2 to the axel hangers Tack weld in detail #1 with the steering neck Check to make sure all components are straight, then tack weld Once complete remove the frame, weld completely, and then move onto the drive train COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

116


Mini Chopper #8 The High Boy WIDE TIRE FRAME SERIES

REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10 FRONT TIRE 20” BICYCLE ENGINE SIZE 2-9HP


117



118





119



Tube length 36.0”, Diameter 1.0”, Wall thickness .083” Two bends required


Tube length 31 7/8”, Diameter 1.0”, Wall thickness .083” One bend & two notches required


120



Tube length 21 3/8”, Diameter 1.0”, Wall thickness .083” One notch required


For the engine mount plate use a 12” X 7 3\4” plate 3\16” thick Transfer the holes from the engine to mount in the proper location


121





122


Detail #8 & #9 • • •

For this detail use a 1” Diameter, .083” Wall D.O.M Tube, 10 3/8” long Make one bend & two notches This detail does not have to be exact. It will hold the jack shaft mounting tabs


123


The High Boy Side Profile


124


The High Boy Jig Plans


125


• BE SURE TO SCREW THE JIG TOGETHER • DO NOT NAIL • PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT CRACK THE WOOD


126



127


• • • • • • •

Load details 3, 4, & 5 into the jig Weld detail #1 to the steering neck outside of the jig Screw or clamp the axel hangers into position Tack weld detail #2 to the axel hangers Tack weld in detail #1 with the steering neck Check to make sure all components are straight, then tack weld Once complete, remove the frame, weld completely, and then move onto the drive train COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

128


MINI CHOPPER FRONT END PLANS FOR BOTH MEDIUM AND WIDE TIRE FRAMES

Detail # 1 2 3A 3B 4 5 6 7

Material D.O.M D.O.M D.O.M D.O.M PLATE STEEL D.O.M BAR STOCK PLATE STEEL

Wall Thickness .083” Note*** .120” Note*** .120” Note*** .120” SEE DETAIL Note*** .120” SEE DETAIL SEE DETAIL


Length Required 20.0” 7.0” 6.25” 6.25” N\A 40.0” AS REQ’D SEE DETAIL 129


DETAIL #1 • •

Tube length 20 ”, Diameter 7/8”, Wall thickness .083” Two bends required, bend radii is 3.5”

BE SURE TO USE 7\8” DIAMETER TUBE FOR YOUR HANDLE BARS, THIS IS THE INDUSTRY STANDARD. MOST HAND LEVERS AND CONTROLS ARE DESIGNED TO FIT 7\8” HANDLE BARS. IF YOU USE 1” YOU WILL HAVE A TOUGHER TIME FINDING LEVERS


130


Detail#2 • Tube length approximately 8.0 ”, Diameter 1.0”, Wall thickness .120” • Notch for 7\8” handle bars Make the riser to suit your body position. You may also wish to buy a bolt-on type riser. I formed mine by cutting the arc on a 2x6. I heated the tube and bent it to the desired arc. I then welded it to the triple trees.

FRAME DETAIL #3A & 3B STEERING NECKS • •

The most common steering neck is a 1 5\8”, .120”wall piece of D.O.M tube” (this will require two bearings to be pressed-in). This is the best way to go! Some older frames use a 1”, .120” wall tube. This requires no bearings.


131


FRAME DETAIL #4 ** Scale this on a photocopier to use as a tracing template, use the dimensions to check scale accuracy.


132


FRAME DETAIL #5 & #6 •

Tube length 40”, Diameter 1.0”, Wall thickness .120”


133



1\4” PLATE 1.5” X 3.75” Weld this detail to the forks, it can be welded on center or to the inside as shown below


134


Mounting the Forks to the Frame! Option #1 •

Mount the forks to the frame using a 3\4-10nc x 8” or 1\2-16nc x 8” bolt

Option #2 •

You may also choose to replace detail 3 with a 1 5\8”, .120 wall D.O.M tube; this will allow you to use bearings in the neck. You will have to adjust the tube notches on the other frame components.

Option #1

Option #2


135


Jack Shaft Drive 11

5

4 1

10 2

3 7

9 8

6 1 2 3 4 5 6 7 8 9 10 11

Clutch Locking collar Bearing Jack shaft Sprocket Locking collar, bearing, Flangettes 1” Diameter axel shaft & locking key Wheel hub Sprocket hub Rear sprocket Chain to match your sprockets

More Info More Info More Info More Info More Info More Info More Info More Info More Info More Info More Info

The above picture shows a jack shaft set-up, which has been used to redirect power to the opposite side of the bike. To mount a jackshaft you must weld two jackshaft mounting tabs to the frame. See the following page. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Jack Shaft Mounting Info Medium Tire Frame

Wide Tire Frame

For the chain to clear the frame you will need to mount the jackshaft mount tabs above the base of the frame COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Torque Converter Drive A torque converter set up is not as complicated as it may sound. When you buy the unit it comes complete with everything you will need to mount it and use it. In most cases you can install one of these units in about 15 minutes. The unit will bolt to your engine using 4 bolts. The primary drive pulley will mount to your engine’s shaft.

T


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If you choose to use a torque converter set-up you will need to add a roller. I used a roller from a two-stroke dirt bike and mounted a small bracket to the frame. This will act as a support and guide to the chain and keep it from rubbing on the frame.

Comet Torq-A-Verter TAV2-30 COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Live Axels Continued

Above you have a complete live axel set up


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Rear Brakes Below I show a mechanical type brake caliper. This unit will need to be mounted to the frame. There are other options such as hydraulic disc brake set-ups and friction bands. If you are planning to use a mechanical brake system, I suggest the rotary brand mechanical disc brake part# 04-9306.

The rotary brand mechanical brake as shown above is one of the best mechanical brakes available. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Hydraulic Disc Brakes You can dress up your chopper with a tricked-out hydraulic brake system. The rear disc brake can be easily mounted using two bolts as shown below. The pedal assembly will mount the same way.


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Other Rear Brake Options Clutch Band Clutch Band: This style of brake is common on mini bikes. Using an angle iron bracket, it rides on the clutch. As the brake is activated, the band tightens around the clutch, stopping the bike.

Rear Drum Brake Rear Drum: There is also a drum style brake available. I have never used one, but they do look slick.

Caliper Type Disc Brake The caliper brake system shown below rides on the rear drive sprocket. This unit can be mounted by making a custom bracket.

Chain Guard Don’t forget safety! Be sure to protect your little riders by adding a chain guard. This unit is available at mfgsupply.com


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Custom Front Pegs Here are a few screen shots of my tricked-out foot pegs. I wanted a look that was a little different and was quite pleased with the results.


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You can even make the seat • • • • •

Make a seat frame with 2 pieces of plywood cut to fit your frame. Glue high density foam to the plywood Then cover with leather, vinyl or any material you choose Staple the covering to the wood Hot-glue a piece of felt to hide the wood and staples

Choose your look!!!!

• If old school is the look you are after, try adding a solo seat and a set of ape hanger handlebars


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Helpful Info

•

If your seat rides on the fender. Be sure to add supports!!!!!!!!!!!!!!!!!!!!!!!!!!!!

• • • • •

This is when you will want to be sure your engine fits correctly. Also be sure your rear tire has enough clearance. If you are using a rear disc brake, be sure the width of the frame is adequate. Also check for proper alignment from the rear sprocket to the front drive sprocket. I use a long straight edge to be sure they are straight. This is a good time to position the engine mount plate and holes.


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Tube Notch Templates Cut the following templates and tape or scribe the profile onto your tube. You can then grind the contour for an accurate tube notch

SOME PRINTERS MAY DISTORT THE SCALE OF THESE TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO RETURN THEM TO THE PROPER SIZE. THIS CAN BE EASILY DONE BY EXPANDING OR SHRINKING THE DRAWING USING THE PHOTOCOPIER CONTROLS. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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SOME PRINTERS MAY DISTORT THE SCALE OF THESE TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO RETURN THEM TO THE PROPER SIZE. THIS CAN BE EASILY DONE BY EXPANDING OR SHRINKING THE DRAWING USING THE PHOTOCOPIER CONTROLS.


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High Quality Parts TRIPLE TREES AXEL HANGERS & FRONT TIRE MOUNT BRACKETS

AVAILABLE AT https://www.minichopperplans.com/


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Online Part Suppliers U.S Parts Suppliers www.bmikarts.com www.mfgsupply.com www.tricountysupply.com www.gokartsupply.com www.cvmkarts.com http://www.georgessales.com/ www.johnsgokarts.com www.jsesc.com www.crosstec.com www.minibikekits.com

Canadian Parts Suppliers www.gokartexpress.com www.idealkarts.com

Thanks & Good Luck! COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Other Projects Available From

Solution Design 1.5” Diameter tube bender plans 1.0” Diameter tube bender plans 6’ X 10’ Utility trailer plans 2 Seat Dune Buggy Plans 4 Seat Dune Buggy Plans Mini Bike Plans COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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Be Sure To Sign Up At HardCoreMiniChoppers.com Check out the world’s largest mini chopper resource on the web!

HardCoreMiniChoppers.com Here’s a small sample of the topics you can learn from and participate in: • • • • • • •

Frame Building Engines Clutches/Torque Converters Bodywork / Paint Front ends Electrical Bar Stool Racers & Other Custom Rides

Some of the most knowledgeable builders in the industry call the Hardcore Mini Chopper Forum home….shouldn’t you?

Welcome to Hardcore Mini Choppers COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED

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