03-28-2012, 04:10 AM
... A book I've never read! But being a dummy, I won't let that stop me from building one!
A little disclaimer before the "it would be cheaper just to buy one" crowd shows up: I know it would be cheaper and easier to build one! I've seen a few episodes of shows like American Chopper, and while choppers aren't really my thing, they really made me want to build a motorcycle. Then I started to want to get into stunting and got a 636... an '06 which apparently have weak frames. So that, combined with wanting to make a bike (A frame will have to be close enough for now!), and the stars aligning just right, here I am starting the process! I've never done anything like this before, but I decided to make a WIP thread in case any other intrepid (or foolish!) soul decides they want to give it a try... Maybe they will be able to learn from my process and any mistakes I make! In the words of the great philosopher Jeremy Clarkson "How hard could it be?"
I've put about three days into this so far. I haven't had as much time to work on it as I would have liked, but I'm almost done with the frame jig. I started with 10' of 2x2x0.093" tubing, 10' of 1.5x0.125" strap, and 20' of 1x1x0.065 tubing (although I don't think I'm going to need the other 10' of it) I'm also using various lengths of 1/4" and 1/2" bolts and machining bushings to match the OD of the bolts to the ID of the frame mount points. I'm making it up as I go along and going kind of slow to make sure after each hard point is welded on that the jig doesn't warp at all and the bolts still slide in and out easy. I think a little extra effort now will save me a lot of heartache when it comes time to make the frame and fit it the the rest of the bike!
So the first thing I made was a couple of tapered plates to hold the neck in place with some 5/8" all thread.
The base frame is made of pieces 4' x 15" although I didn't end up going with a box like you see here.
Here are the first two mount points! I centered the frame by machining one end of the all thread to a point and putting that on a center mark on the front of the jig. Then I used the inner face of the tank mounts to get it centered in the back because I knew those were symmetrical.
Second two mount points done! Once the first two were done, I more or less leveled the frame by extending the all thread. I'm going off the top surface of the frame for "level". To get the height measurement for the holes, I made the aluminum bushings, then inserted a piece of metal 0.25" diameter and machined to a point. I used a big set of calipers to measure from the point to the top of the base and used that number in the mill to drill the holes. The plates slid right into place as expected and were then welded!
Swingarm bolts in place! The blue tape is reminding me that I won't be needing to put a mount for that hole
Finally, here it is as it sits right now. The cross brace is held in place by two bolts so it can be removed so I can remove the frame! I welded on two pieces of angle iron, and then drilled through them and the tube... because I was just drilling with a cordless drill the holes came out a little off round so while it was still clamped, I put on two small strips of strap to further help locate the cross bar, it will also keep the two lower support bars at the right spacing. The top shock mount is also a piece of angle iron welded onto the back of the tube.
Here is a close up of the cross brace area.
Hopefully I'll be able to get some time to finish the Jig tomorrow. I just need to put some mounts for the lower shock and the other three sub frame mount points and then maybe add some cross braces to make sure it is solid.
A little disclaimer before the "it would be cheaper just to buy one" crowd shows up: I know it would be cheaper and easier to build one! I've seen a few episodes of shows like American Chopper, and while choppers aren't really my thing, they really made me want to build a motorcycle. Then I started to want to get into stunting and got a 636... an '06 which apparently have weak frames. So that, combined with wanting to make a bike (A frame will have to be close enough for now!), and the stars aligning just right, here I am starting the process! I've never done anything like this before, but I decided to make a WIP thread in case any other intrepid (or foolish!) soul decides they want to give it a try... Maybe they will be able to learn from my process and any mistakes I make! In the words of the great philosopher Jeremy Clarkson "How hard could it be?"
I've put about three days into this so far. I haven't had as much time to work on it as I would have liked, but I'm almost done with the frame jig. I started with 10' of 2x2x0.093" tubing, 10' of 1.5x0.125" strap, and 20' of 1x1x0.065 tubing (although I don't think I'm going to need the other 10' of it) I'm also using various lengths of 1/4" and 1/2" bolts and machining bushings to match the OD of the bolts to the ID of the frame mount points. I'm making it up as I go along and going kind of slow to make sure after each hard point is welded on that the jig doesn't warp at all and the bolts still slide in and out easy. I think a little extra effort now will save me a lot of heartache when it comes time to make the frame and fit it the the rest of the bike!
So the first thing I made was a couple of tapered plates to hold the neck in place with some 5/8" all thread.
The base frame is made of pieces 4' x 15" although I didn't end up going with a box like you see here.
Here are the first two mount points! I centered the frame by machining one end of the all thread to a point and putting that on a center mark on the front of the jig. Then I used the inner face of the tank mounts to get it centered in the back because I knew those were symmetrical.
Second two mount points done! Once the first two were done, I more or less leveled the frame by extending the all thread. I'm going off the top surface of the frame for "level". To get the height measurement for the holes, I made the aluminum bushings, then inserted a piece of metal 0.25" diameter and machined to a point. I used a big set of calipers to measure from the point to the top of the base and used that number in the mill to drill the holes. The plates slid right into place as expected and were then welded!
Swingarm bolts in place! The blue tape is reminding me that I won't be needing to put a mount for that hole
Finally, here it is as it sits right now. The cross brace is held in place by two bolts so it can be removed so I can remove the frame! I welded on two pieces of angle iron, and then drilled through them and the tube... because I was just drilling with a cordless drill the holes came out a little off round so while it was still clamped, I put on two small strips of strap to further help locate the cross bar, it will also keep the two lower support bars at the right spacing. The top shock mount is also a piece of angle iron welded onto the back of the tube.
Here is a close up of the cross brace area.
Hopefully I'll be able to get some time to finish the Jig tomorrow. I just need to put some mounts for the lower shock and the other three sub frame mount points and then maybe add some cross braces to make sure it is solid.
Originally Posted by TL MILLER
