Mini Chopper Plans
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(2) 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. 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.
(3) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 3.
(4) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 4.
(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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 5.
(6) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 6.
(7) 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 #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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 7.
(8) 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. 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 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.
(9) 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 DETAIL #1 • •. Tube length 34.0”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 9.
(10) 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 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 10.
(11) 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 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 11.
(12) 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 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 12.
(13) 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 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). COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 13.
(14) 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 DETAIL #5a • •. 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). COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 14.
(15) 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 DETAIL #6 • •. Tube length 20 7/16”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 15.
(16) 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 DETAIL #7 •. Tube length 18.5”, Diameter 1.0”, Wall thickness .083”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 16.
(17) 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 DETAIL #8 • • •. Tube length 9.0”, Diameter 1.0”, Wall thickness .083” Two notches required 3 of these required for seat & jack shaft mounting. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 17.
(18) 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 DETAIL #9 • •. Tube length 10 3\32”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 18.
(19) 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 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 19.
(20) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 20.
(21) 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 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 21.
(22) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 22.
(23) 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. Medium Tire Frame Jig Bill Of Material. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 23.
(24) 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 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.
(25) 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. 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!. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 25.
(26) 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. Medium Tire Frame Side Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 26.
(27) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 27.
(28) 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 #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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 28.
(29) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 29.
(30) 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 DETAIL #1 • •. Tube length 34 1\4”, Diameter 1.0”, Wall thickness .083” One notch required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 30.
(31) 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 DETAIL #2A & 2B • •. Tube length 14 3\4”, Diameter 1.0”, Wall thickness .083” One notch required per detail. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 31.
(32) 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 DETAIL #3 & 4 • •. Tube length 53 1\4”, Diameter 1.0”, Wall thickness .083” One notch required per detail. FRAME DETAIL #5 • •. Tube length 9.0”, Diameter 1.0”, Wall thickness .083” Two notches per detail. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 32.
(33) 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 DETAIL #6 • •. 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 33.
(34) 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. ENGINE MOUNT PLATE DETAIL •. Use 1\8” mild steel plate. FORK DETAILS •. Use 1 1\2” .085” wall tube. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 34.
(35) 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. Little Tyke Rear Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 35.
(36) 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. Little Tyke Frame Dimensions. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 36.
(37) 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. The Little Tyke Jig Bill Of Material. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 37.
(38) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 38.
(39) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 39.
(40) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 40.
(41) 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 Assembly Information. • • • • •. 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.
(42) 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 #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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 42.
(43) 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. 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 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) 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 DETAIL #1 • •. Tube length 38 11/32”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 44.
(45) 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 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 45.
(46) 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 DETAIL #3 • •. 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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 46.
(47) 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 DETAIL #4 • • •. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 47.
(48) 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 DETAIL #5. • •. 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). COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 48.
(49) 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 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). COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 49.
(50) 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 DETAIL #6 • •. Tube length 20 7/16”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 50.
(51) 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 DETAIL #7 Tube length 23.0”, Diameter 1.0”, Wall thickness .083”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 51.
(52) 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 DETAIL #8 • •. Tube length 12.5”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 52.
(53) 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 DETAIL #9 • •. Tube length 11 1/8”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 53.
(54) 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 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 54.
(55) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 55.
(56) 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 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 56.
(57) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 57.
(58) 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. Wide Tire Frame Jig Bill Of Material. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 58.
(59) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 59.
(60) 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 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. 60.
(61) 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. 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!. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 61.
(62) 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. WIDE TIRE FRAME DIMENSIONS. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 62.
(63) 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 #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”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 63.
(64) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 64.
(65) 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 DETAIL #1 • •. Tube length 37 5/8”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 65.
(66) 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 DETAIL #2 • •. Tube length 30 3/4”, Diameter 1.0”, Wall thickness .083” Two notches required. FRAME DETAIL #3 •. Tube length 12 1\2”, Diameter 1.0” Wall thickness .083”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 66.
(67) 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 DETAIL #4 • •. Tube length 53 1\4”, Diameter 1.0”, Wall thickness .083” One notch required. FRAME DETAIL #5 • •. Tube length 53 1\4”, Diameter 1.0”, Wall thickness .083” One notch required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 67.
(68) 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 DETAIL #6. • •. Tube length 11 1/8”, Diameter 1.0”, Wall thickness .083” Two notches required. Engine Plate Detail •. Use 3\16” thick mild steel plate. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 68.
(69) 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 Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 69.
(70) 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. The Brute Jig. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 70.
(71) 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. • Screw together - Do not nail. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 71.
(72) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 72.
(73) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 73.
(74) 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. • • • • • • •. 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.
(75) 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 #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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 75.
(76) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 76.
(77) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 77.
(78) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 78.
(79) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 79.
(80) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 80.
(81) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 81.
(82) 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. 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. •. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 82.
(83) 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. BLACK WIDOW JIG. This is the most important step in building your frame; this jig will ensure the frame is assembled straight and accurate. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 83.
(84) 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. Black Widow Jig Bill Of Material. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 84.
(85) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 85.
(86) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 86.
(87) 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 Assembly Information. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 87.
(88) 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. Black Widow Frame Side Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 88.
(89) 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. Black Widow Rear Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 89.
(90) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 90.
(91) 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 #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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 91.
(92) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 92.
(93) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 93.
(94) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 94.
(95) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 95.
(96) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 96.
(97) 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. 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 97.
(98) 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. The HULK JIG. This is the most important step in building your frame; this jig will ensure the frame is assembled straight and accurate. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 98.
(99) 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. The Hulk Bill of Material. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 99.
(100) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 100.
(101) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 101.
(102) 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 Assembly Information. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 102.
(103) 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. The Hulk Frame Side Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 103.
(104) 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. The Hulk Rear Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 104.
(105) 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 #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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 105.
(106) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 106.
(107) 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 DETAIL #1 • •. Tube length 33 1/4”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 107.
(108) 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. The Low Boy Side Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 108.
(109) 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. The Low Boy Jig. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 109.
(110) 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. • BE SURE TO SCREW THE JIG TOGETHER • DO NOT NAIL • PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT CRACK THE WOOD. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 110.
(111) 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 DETAIL #2 & #3 • •. Tube length 36.0”, Diameter 1.0”, Wall thickness .083” Two bends required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 111.
(112) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 112.
(113) 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. 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 113.
(114) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 114.
(115) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 115.
(116) 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. 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.
(117) 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 #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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 117.
(118) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 118.
(119) 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 DETAIL #1 • •. Tube length 36 1/8”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 119.
(120) 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 DETAIL #2 & #3 • •. Tube length 36.0”, Diameter 1.0”, Wall thickness .083” Two bends required. FRAME DETAIL #4 & #5 • •. Tube length 31 7/8”, Diameter 1.0”, Wall thickness .083” One bend & two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 120.
(121) 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 DETAIL #6 • •. Tube length 21 3/8”, Diameter 1.0”, Wall thickness .083” One notch required. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 121.
(122) 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 DETAIL #7 • •. Tube length 11 1/16”, Diameter 1.0”, Wall thickness .083” Two notches required. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 122.
(123) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 123.
(124) 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. The High Boy Side Profile. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 124.
(125) 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. The High Boy Jig Plans. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 125.
(126) 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. • BE SURE TO SCREW THE JIG TOGETHER • DO NOT NAIL • PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT CRACK THE WOOD. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 126.
(127) 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 127.
(128) 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. • • • • • • •. 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.
(129) 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 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. Length Required 20.0” 7.0” 6.25” 6.25” N\A 40.0” AS REQ’D SEE DETAIL 129.
(130) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 130.
(131) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 131.
(132) 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 DETAIL #4 ** Scale this on a photocopier to use as a tracing template, use the dimensions to check scale accuracy.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 132.
(133) 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 DETAIL #5 & #6 •. Tube length 40”, Diameter 1.0”, Wall thickness .120”. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 133.
(134) 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 DETAIL #6 • •. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 134.
(135) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 135.
(136) 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. 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. 136.
(137) 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. 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. 137.
(138) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 138.
(139) 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. 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. 139.
(140) 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. Live Axels Continued. Above you have a complete live axel set up. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 140.
(141) 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. 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. 141.
(142) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 142.
(143) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 143.
(144) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 144.
(145) 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. 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. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 145.
(146) 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. 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.. COPYWRIGHT 2002, SOLUTION DESIGN NOT TO BE RESOLD OR CIRCULATED. 146.
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