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Build Your Own Custom Motorcycle

Build Your Own Custom Motorcycle

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Build Your Own Custom Motorcycle
Build Your Own Custom Motorcycle

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Published by: Mark Thatdamwabbit Edwards on May 10, 2012
Copyright:Attribution Non-commercial

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08/21/2013

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Build Your Own Custom Motorcycle
Stage 1 - rear assembly| Stage 2 - rear hot mock-up|Stage 3 - front dissembly|Stage 4 - frame geometry|Stage 5 - front modification|Stage 6 - full hot mock-up|Stage 7 - test ride |Stage 8 - paint preparation|Stage 9 - paint process |Stage 10 - final assembly  Chopper Assembly - Assemble it for the first ride, make sure all parts fit before paintingEngine Mount/Frame Gusset : The engine was placed into the frame for proper alignment of the uppermotor mount. A small piece of tubing is cut and bolt is welded to the back and attached to the enginemount. Tubing is then cut to connect the mount to the frame and it spot welded into place.The neck brace was then cut and spot welded into place.Tank Mount: The Fuel Tank is set in place using precision alignments tools(drywall screws). With the tankcentered, the mounts were spot welded to the backbone. The rear mount was welded first, followed by thefront mount.
 
Voltage Regulator Mount: The stock voltage regulator and master cylinder bracket was saved and placeonto the new downtubes. The downtube welds have also been grinded in this photo, a polyester glazingputty will be used before painting.Ignition Switch Mount: The ignition switch is mounted under the tank and is attached to the upper enginemount. A 1.5in tube was cut to house the new switch and a endcap was added. Sheet metal is then addedto complete the look.Tank Sheet Metal: Sheet metal is added under the tank to hide the wire harness and provide a clean look.Using card board templates first, the sheet metal is then cut and welded into place. 3 different sections of metal are used, after the polyester is applied, it will look like one section.
 
Cosmetic Tank Extension: The WCC tank ends just before where the stock seat pan meets the frame, ourseat location has been moved back and lowered. To fill this gap, a "fake" tank Extension is added bywelding in steel rod to create a point. This will be filled with Polyester and sanded to match the tankcontour.Swing Arm, Wheel, and Fender: A custom 2" tube was added to the swing arm mount to hide the exposedswing arm bearing extension that was added previously. The rear wheel was them mounted and the fenderwas bolted on.Don't forget to add the drive belt...Trees, Fork Tubes, and Wheel: The 7* triple tress were installed and the 10" over fork tubes were then slidinto place. The front wheel was then mounted.

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