How To Build A

Mini Chopper!

by Custom-Choppers-Guide.com
Copyright
All Rights Reserved.
If you are new to such projects, it is strongly recommended
that you do an assembly job, purchasing pre-constructed
parts such as the frame, front end, axel set-up, etc. You may
even want to start with an assembled bike, strip it, and rebuild it
with customized parts.

If you are planning to build a bike from scratch, then you will
need to begin by cutting and bending the piping for the frame,
then assembling the frame in a custom-made jig. For this, you
will need access to a tube-bender, welder, and the
professional skills to use both.

Before you decide which route to take, read this document and
discuss your potential project with an experienced professional.
Full Bike Kits

One option in building a mini chopper is purchasing a full bike kit.

There are two basic kinds of kits:

Stage I Kits include:

 large scale plan

 detailed building instructions
 axle plates
 steering neck tube
 pre-cut and pre-bent tubing (without the connection miter cuts)

Find Good Used Mini

Choppers Here.
Stage II Kits include:

• large scale plan

• detailed building instructions
• axle plates
• steering neck tube
• pre-cut and pre-bent tubing (with the connection miter cuts)
• pre-drilled mount plates for the motor
• transmission
• oil tanks
• forward controls

If motorcycle building is a new field for you, then a kit is a wise

choice.
 The Frame

You have three basic options when it comes to obtaining a frame

for your mini chopper.

1. Purchase an existing cycle and strip it down to the bare frame.

2. Purchase a pre-manufactured frame.
3. Build a frame from scratch.

For first time builders, the first method is highly recommended. It is

a valuable learning experience to strip a bike. You can see, as you
take it apart, how it was put together. Plus, modifying an existing
bike is usually far less expensive and complicated than building
one.
The second option above is a good option for someone
wanting to try his hand at building a bike from the
bottom up without dealing with the issues of tube-
bending and welding.

Instead of building from scratch, you are assembling from

parts. There are some great kits available for mini choppers.
There are frame kits, front end kits, and full bike kits
(discussed earlier).

The third option is obviously the most complicated and time

consuming of the three options. For this option you will need
the following parts:
 Frame Items for Construction

(Items do not correspond to numbers in illustrations below.)

Axel Hangers  Purchase or construct

Engine mount plate  Purchase or construct
Fender mount brackets  Construction necessary
Fender supports  Construction necessary
Frame D.O.M. (tubing)  Purchase
Front Gusset  Construction necessary
Steering Neck D.O.M.  Purchase or construct

As for tubing, D.O.M. tubing is recommended for its true diameter.

An imperfect diameter will result in weak bends.
The two pieces labeled #3 and the piece
labeled #6 can be cut and bent first. These
can be assembled in the base of the jig
(discussed in the next section). The
remainder of the pieces can be measured
and bent as the frame is being suited to the
jig. This will allow for accurate
measurements and balanced assembly.

For pieces #3, you can use a length of

between 37 and 40 inches (what ever
length you decide, make the two pieces
identical). Then, you can bend them at 75°.
For piece #6, you can use a length of
between 18 and 19 inches.

When assembling the frame in the jig, tack

welds are recommended so that
adjustments can be made if necessary.
The Jig

Using a jig is absolutely crucial for frame assembly. The

jig will ensure that your frame is straight and accurate.

Many first-timers believe the jig must be extremely

accurate and built with minute precision. At the same
time, they believe the jig must possess great strength for
bending tubing and holding it in position for welding.
This is not the case.

You can use any relatively stable structure as the

backbone of a jig. A homemade jig is as uniquely
constructed as a custom bike.

If you are not comfortable constructing a jig, and you

want to make sure your frame construction is solid
(which is necessary), then you can buy a jig (or even
borrow one). Many jigs are made to be adjusted to fit
the specs of different frames.

There are three basic types of jigs for welding

motorcycle frames.
Full Bike Jig

This kind of jig is designed to accept the many

components for the bike, such as wheels, engine and
transmission case.

Frame Jig

This kind of jig is designed specifically for holding the

frame tubes in position while you weld. This type of
jig has very little flexibility for custom work.

Fixture Jig

This kind of jig is designed for holding a specific

portion of the frame. It is essentially a sub-jig,
holding specific pieces, such as the engine mount
plate.
 The Front End

When it comes to front ends, there’s no perfect formula. A certain amount of

experimentation is always needed to suit the individual bike and the individual rider.
Riding and handling characteristics are, to a certain degree, a matter of taste and
preference. Plus, the fork system is not the only factor in the riding and handling. Other
factors include weight distribution, total weight, neck height, tire and wheel size, etc.

The most common question concerning front ends is, “How long do the forks need to be
for a particular rake?” The answer, though, depends upon a wide variety of factors and is
almost always specific to one particular cycle. It is possible to use a CAD program to
compute the length, but this will not work as well as actually making a mock-up of the
bike, which consists of setting the frame on blocks of cribbing to get the frame level with
the desired amount of ground clearance. At this point, you can measure through the
steering head to the imaginary front axel.

The mock-up measurement is, of course, an imperfect science, and these measurements
usually come out short due to a number of factors, including misplacement of the
imagined centerline and a lack of considering fork offset. Thus, it is a good idea to add
two inches the length you estimate, maybe more; it is better to err on the long side than
the short side. You can always cut them down.

There are basically four different types of forks available today.

Rigid

With rigid forks, there are no suspension links because the side rails or tubes are bolted
solidly to the yokes or trees. These lack effective cushioning except on bikes with
extreme amounts of rake and relatively low steering neck heights.

Telescopic or Hydraulic

Most bikes on the road use telescopic, or hydraulic, forks, which have been often
compared to two giant pogo sticks. These forks, though, don’t work extremely well on
radically raked front ends.

Springers

There are several derivatives of Springer forks, but basically they are built with springs to
give them shocks.

Girders

Girder fork designs are adaptable to virtually any chassis. They provide excellent handling
characteristics over a broad range of steering neck rake angles. And they can be very
strong, yet lightweight. The only reason that Girders aren’t on more bikes is because they
are expensive to manufacture and should be custom made for a specific frame
configuration.
Front End Items for Construction

(Numbers in list do correspond with numbers in illustration

below.)

1. Handle bars  Purchase or construct

2. Handle bar risers  Purchase or construct
3. Triple Trees  Purchase or construct
4. Plate  Construction necessary
5. Front fork tubes  Construction necessary
6. Support Brace  Construction necessary
7. Front tire mount brackets  Purchase or construct
Drive Train

As for your drive train, you have two viable options, a jack shaft drive or a torque
converter drive. The latter is shown here.

Engine Drive Train Items

• 3.5hp – 6hp side shaft engine  Purchase

• Chain length to suit option 1 or 2  Purchase
• Option #1 standard clutch & jack Shaft set-up  Purchase
• Option #2 belt driven torque-Converter set-up  Purchase

Torque Converter

A torque converter set-up is to be purchased complete with everything you need for
mounting and operating. Basically, you will mount the primary drive pulley to the shaft
of your engine using the provided bolts. You may also want to add a roller to keep the
chain from rubbing the frame.

The torque converter offers lower gears (meaning greater torque and acceleration) and
higher gears (meaning potential higher top speeds). Yet, these qualities may not be
desirable. It’s, of course, a decision that each individual must make.
 Rear Axel
Below is an axel set-up.
The most common axle set-up used on mini choppers
is a live-axle. The word "live" means that the axle spins
along with the wheel and sprocket, and bearings must be
mounted to the swing arm frame.

This set-up is simple with easily changeable components.

Each piece (sprocket, wheel hub, disc brake rotor, etc.)
slides onto the axle and is held in place by locking collars.

You can purchase complete live-axel kits with assembly

instructions included.
 Rear Wheel Items for Assembly

1” Diameter bearings  Purchase

1” Diameter live axel with retainers  Purchase
Axel hangers  Purchase
Bearing cages  Purchase
Front brake lever and cable  Purchase
Rear disc  Purchase
Rear disc hub  Purchase
Rim hub  Purchase
Rear tire size 18.8-8.5-8 for wide tire Frame
or 15-6.00-6.00 for medium tire frame  Purchase
Rear Rim 4 bolt  Purchase
Rear sprocket  Purchase
Rear sprocket hub  Purchase
Throttle assembly  Purchase
 Rear Brake
Here is a mechanical brake caliper.
 Other Options

Clutch Band Rear Drum Brake

This is a common style of brake. This is a less common option.
 Seat and Gas Tank

If you prefer, you can make your own seat with plywood, glue, foam, leather or
vinyl.

Custom Items

Gas Tank  Purchase

Kick stand  Construction necessary
Rear fender  Purchase
Seat  Purchase or construct
 Conclusion

At this point, you have some decisions to

make. After deciding the path best for you,
remember to plan thoroughly, measure twice
and cut once, take all safety precautions and
have your work checked by a professional. Be
responsible in your building and your riding,
and don’t forget to have fun!

Here’s where to find parts for

your mini chopper!
 Whether you want to build a
custom mini chopper, custom
chopper, or custom motorcycle
this is the best DVD set on how
to do it yourself: Highly
recommended.