In addition, all material standards that will be acceptable, and expectations of the overall design should be clearly outlined.īefore any successful project fabrication starts, the designer must have a goal in mind, as well as product expectations or there could be chaos.
HOW TO BUILD GIRDER FORKS CHOPPER BUILDERS HANDBOOK PLUS
Standards would include definitions of all materials used plus the definition of an acceptable weld and overall workmanship. The designer should define the standards to which the frame is to be made, and demand that those standards be adhered to. Any compromise in frame integrity could result in premature failure and personal injury to the rider, or even death. The miter joints must be done properly and the welds must meet established minimum standards.
Tubing is tubing, and pipe is pipe, and never the twain shall meet! Don't be fooled into thinking that you can use a pipe or conduit bender for bending tubing. Some tube bending machine suppliers emphatically state that you absolutely cannot use a pipe-bending machine for tubing. Another difference is the wall thickness.įor our example projects, we are using tubing with a 1.25" diameter, and a 0.125" wall thickness. The answer is.not if the inside diameter (I.D.), and tubing is measured by the outside diameter (O.D.). You will also find several other suppliers in the RESOURCE section.Ī common question is whether or not a pipe bender can be used to bend tube. Another supplier of tube benders is Williams Lowbuck Tools, Inc. The link to their site is located in the RESOURCE section of this document. One supplier for tube bending and tube notchers is Pro-Tools from Tampa, Florida. These tools come in all shapes, sizes and prices. This picture demonstrates the use of the Angle Finder in determining that the geometry of the tubing is as it should be. Many builders use actual major components such as engine, transmission, rear wheel and front forks to ensure accuracy of alignment. As long as the jig base (parallel rails) and the vertical assemblies are perpendicular to the parallel base rails, accuracy will be achieved in the frame. There are four leveling adjustments on the feet extending out from the parallel rails. Notice the adjustments that are available for the steering neck, rear axle plates and seat post. To the above right is an example of a builders Jig.
If you tackle this job yourself, remember, it will always remain a "work-in-progress" as you fabricate your frame. To build a jig yourself, and I mean all the machining and other work yourself, you will have to invest anywhere from $200 to $700 in materials alone. In either case, the cost would be prohibitive to the small shop or the individual builder. The jig would have to be tailored to the bike design, or be infinitely variable. The beginning price could be anywhere from $5,000 upwards for an adjustable jig. Commercial chopper frame jigs are very expensive.
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