View Full Version : '66 Honda Trail 90 Chopper - Live slow/ die whenever

02-08-2015, 5:24 PM
Long time lurker here. I've gotten loads of inspiration from other folks' builds, so I figured it was about time to start posting my own stuff.

First off, a little about me - I like small bikes. Mopeds, little hondas, hell even a scooter once in a while. I've got nothing against larger machines, but for now I'm content going slow and looking ridiculous while doing so.

A few years ago I really wanted to build myself a nice little trail 90. I scoured craigslist until I found a parts lot of about 2-1/2 bikes.

From the 2 rollers, I pieced together a sweet little 140cc screamer in about 3 months.


For more on that bike you can check it out here (http://advrider.com/forums/showthread.php?t=910629)

That bike was fun as hell to build, and even more fun to ride, but that's not what this thread is about... This thread is about the 1/2 bike I got in the craigslist sale. Ok, it was TWO halves of a '66 trail 90 frame. Litterally, someone cut the damn thing in half. For what reason, I don't know. I stared at those pieces of bike until one day, the inevitable mock-up happened.


02-08-2015, 5:35 PM
Even though the flipped head tube provided some additional rake, it wasn't enough, so I cut some more.


Got a few pieces of pipe and stretched the underbone frame "6 over stock




I managed to track down a motor from a trail 70 to use. I could very well have just bought a Chinese pit-bike motor, but rebuilding OEM shit is more satisfying.
Having the frame and motor mocked up on a table, I decided this bitch needs a skirt. A piece of sheet metal from homedepot and a few hours later I had this:


This was my first attempt at any sheet metal beating. I was quite happy with the results.

02-08-2015, 5:53 PM
The skirt is held on with a few small studs welded to the inside of the fender. Simple, but it works.

I made some struts from scrap pipe hanging around the garage.


Since I had to deal with the chain drive on the left side of the bike, I couldn't just jump into the second wheel skirt right away. I found this chain guard from some old bicycle on ebay, and took a chance on it.


As luck would have it, perfect fit.


Hours of hammering, cutting, bending, and cursing later I had this:


More mocking up, and an extremely clean gas tank/ seat pedistal off ebay for $10\


02-08-2015, 6:04 PM
I knew I needed some weird bars to go with the leading-link front forks. So I bought some 7/8" pipe, threw a jig together, and grabbed the torch.



Got em chopped and welded, now they just bolt on to the top of the forks. If you look closely, you can see the shifter poking up off the frame, and linkages hangin down.


Last summer I did manage to spray a few pieces to get a taste of what the paint will look like... rattle cans under automotive clear.

I'm still going on this bike, but that's all I have for pictures at the moment. Even under all this snow here in the Northeast, I've managed to get a few more things done - even managed to get it running. This is my first really custom build. It's been such a great release to just get the creative juices flowing. I'll get some more pictures taken and posted if anyone's interested.


02-08-2015, 7:29 PM
haha this is so whacky I'm into it

I also want to know how you did a 140cc conversion. I would like to soup this thing up http://www.chopcult.com/uploads_user/15000/14574/90514.jpg

02-08-2015, 9:06 PM
Why do I like this so much? I think it's awesome that you are chopping what you have.

02-09-2015, 5:24 AM
Looks good to me really like the skirts keep up the progress.

02-09-2015, 6:26 AM
Thats gonna be sweet!

02-09-2015, 11:42 AM
I love what you're doing to this Trail. Looks great so far!

02-09-2015, 12:05 PM
Haha! I LOVE this thread. Keep it up!

02-09-2015, 3:35 PM
haha this is so whacky I'm into it

I also want to know how you did a 140cc conversion. I would like to soup this thing up http://www.chopcult.com/uploads_user/15000/14574/90514.jpg
Damn, that's a clean little honda.
The engine on the trail bike is a crate LIFAN 140cc. Bolted up with some minor clearance grinding on the frame. The 140 has to run an oil cooler. Smaller (110s, 125) engines can get by without them. Wiring was all redone from scratch. Now 12v with cdi. You can buy the motors with everything you need to run for around $500

Thanks for the feedback folks. I'll try to make my way to the garage for some current pics of the chopper.

02-09-2015, 4:16 PM
Here's a shot of the custom intake I hacked together to mount my downdraft carb. Eventually gonna rock a velocity stack.


I rebuilt the top end of the motor, along with an 88cc kit. It should have some decent pep.

I'm running an internal throttle utilizing honda z50 parts.


My most recent progress on the bike includes the fabrication of this ridiculous exhaust. Might do a fishtail tip.






02-09-2015, 6:03 PM
my old pushrod engine is able to wheelie I can't wait to see a wheelie vid from you.

totally whacky and awesome, bravo

02-10-2015, 6:08 AM
this is looking really cool.
love it.

02-10-2015, 6:47 AM
My first bike after my tube frame mini bike was a step through Honda 50. It was a hand me down from my dad. He used to haul it in the back of his airplane. The down tube was cut similar to your pic only further up. It had a special sleeve with clamps and roll pins to hold it together. The electrics were modified with a cannon plug and the throttle slide would be removed from the carburetor and a special threaded container screwed over the slide and that set up allowed the front end to be free from the rest of the bike. It was a commercial aftermarket mod offered by the dealer. Seeing your cut down tube brought back the memory of this. Tough little bikes, I tried to tear it up but it withstood my abuse. I like what you are doing with your bikes, different and creative. Not everybody needs a '47 Knucklehead.

02-10-2015, 7:55 AM
This site is just awesome. You guys are just artists.

02-10-2015, 7:03 PM
4 Door....fuckin sweet brother !!!!....this is the kinda shit I was doin in the 70s....I love that you younger guys are keepin it up !!!!
Id add a rib to that backbone tube though....I had an M50 Suzuki I commandeered outta Cambodia...same type of "no lower" frame, but mine was stamped steel (1965 ???)...It ended up raking itself when I went over a big hump, and the frame broke just behind the neck....luckily, not all the way through....

Or add a top tube...new gas tank...make a triangle in the frame though please....

02-10-2015, 9:17 PM
LOVE it! I restored a 1980 Trail 110 for a friend a few years ago. It was a fun bike, but he beat the shit out of it in the mountains out here and "blew the tranny" (lmfao). We are in the process of putting a Lifan 125cc in it now. I want to cut it up a bit, but not my bike.

02-12-2015, 7:33 PM
I've seen a couple of these chopped... love how it sticks in period correct craws, and I don't know why. I like what you've been doing to this one a lot... I really hope those bars from hell aren't quite finished yet though.

02-12-2015, 8:07 PM
Not everybody needs a '47 Knucklehead.

Ok I really dig this but really? Everyone NEEDS a '47 Knuck.

02-12-2015, 8:24 PM
Ok I really dig this but really? Everyone NEEDS a '47 Knuck.


02-14-2015, 7:23 PM
Id rather have a Pan....but this is a whole nuther animal now, aint it ?...and Im diggin the shit outta it !!!!....I gotta find similar to play around with next winter....mebbe a Trail 90 or Trail 70 cafe racer ???...mwaaaa haaa haaaa.....2 range gearbox...(tech 8 speed)....add a smaller rear sprocket for more top end....port it, higher comp, and shitcan the USFS approved spark arrestor muffs....drag bars, then a small fairing....oh yeah....the gears are turnin.....

02-14-2015, 8:22 PM
Can't wait to see the final product, sounds sick btw.

02-23-2015, 6:26 PM
Thanks for the support dudes! No, I wouldn't mind having a '47 Knuck, hahaha.

I've been getting some shit done indoors lately. Fuck this winter.

Front wheel: rusty, crusty, and wobbly as shit. It's seen more than it's fair share of off-road abuse, I'm sure.

Brake plate:

Cleaning the gunk off the brake plate with my Harbor Freight sonic cleaner (love this thing)

After a little fluff and buff with the dremel, I got a nice shine on the aluminum.

Since the rim was fucked, I decided to buy a new set of hoops & spokes, and have a go at lacing it up myself. My first time attempting this. Parts came in today so I got to work after work.


Got it laced up pretty damn close to true, so I just threw the tire on there. Might buy a truing stand and get it perfect... then again, I won't be going for any land speed records.


Also, I made this fishtail. Not sure if I want to use it. I ran it on the end with a magnet, and it kind of changes the exhaust note to a tinny 2 stroke pitch.

02-23-2015, 9:28 PM
Wow! that cleaner did a great job! what are the dimensions on that puppy? I've been dreading the parts cleaning on my project, and that'd be awesome.

02-23-2015, 10:06 PM
About 11"x8", 4" deep. Great for small stuff, like carbs. Here's the downdraft carb on the bike before the parts cleaner - it was frozen solid.http://i182.photobucket.com/albums/x264/4Doora/Chopper%20ct200/chopper065.jpg (http://s182.photobucket.com/user/4Doora/media/Chopper%20ct200/chopper065.jpg.html)

The brake plate and hub took a lot of sanding and polishing to get the shine, but the ultrasonic cleaner got the first layer of grime. I use it with "awesome orange" from the dollar store.

03-03-2015, 5:59 PM
One great thing about building small bikes - it's easy to get them in your bedroom.
Ok, so I haven't really got any shit done aside from bolting on the front wheel and starting on my backwards brake lever... but at least I can show you all what my headlight setup is going to look like.

03-04-2015, 1:04 AM
Really cant wait to see this wee beast finished and rippin roads. I love the light set up

05-30-2015, 7:23 AM
This is too fucking cool. My ex and I picked up two trail 90's some years ago. The deal was the first was hers to be restored and the second would be mine to chop up and have fun with. She lost motivation and then we split and she wouldn't let me have either one. Now they're sitting in her garage just wasting away like her ninja. Kills me. I'd love to see some updates on this. The front end is killer.

05-30-2015, 8:57 AM
almost forgot about this thread- MORE PLEASE!

05-30-2015, 3:46 PM
One great thing about building small bikes - it's easy to get them in your bedroom.
Ok, so I haven't really got any shit done aside from bolting on the front wheel and starting on my backwards brake lever... but at least I can show you all what my headlight setup is going to look like.

digging the dual headlight, this build is refreshing to see. something different!

05-30-2015, 9:11 PM

06-06-2015, 7:15 AM
This thing is awesome!

06-21-2015, 10:17 AM
It's been quite a while since I touched this bike... life has a way of throwing you curve balls. My girl's father passed away, so the last couple months have been focused on her, and moving in together.
Now that things have slowed down I've been thinking of finishing the bike more and more though. Hopefully I can get this thing painted in the weeks to come and on the road by the end of summer.

06-23-2015, 12:38 PM
sorry to hear about your girls father.

this Bike is coming together nicely cant wait to see more of it

06-23-2015, 1:22 PM
Sorry about your loss. That said, your bike is pretty fuckin' sick! I can't wait to see it finished. :)

06-23-2015, 9:05 PM

This is very cool, what did you use to cut this out?

06-24-2015, 7:15 AM
This is so cool, I love it!

08-07-2015, 4:25 PM
It seems to be getting harder get home to work on my shit, but I managed to get in some much needed therapy today.





Stripes, color, and shine to come.

08-07-2015, 4:50 PM
This is very cool, what did you use to cut this out?

I can't say for sure, but I'd bet it was a combination of a torch for heating (to get the actual bend/rake), and a cut-off wheel on a grinder for the cutting.

08-08-2015, 2:26 PM
Yup, grinder with a cutoff disk. no need to heat though, it's was thin enough to bend by hand.

08-08-2015, 2:42 PM
Awesome scoot!

When I was in Christchurch, NZ, the lady and I had the pleasure of hooking up with the Quake City Rumblers. Really great guys with some rad lil bikes. If it wasn't for the shitty weather (winter was rolling in), being fucked for hours by our employer, and EDR, we definitely would've staying there longer just to be around them some more.

https://www.tumblr.com/search/quake city rumbalers


08-08-2015, 2:50 PM
Oh man, I've been following those QCR dudes for a while on facebook. I love checking up on their bikes / shenanigans.

Here's a little sneak peak at what went on in the garage last night... I went a little nutso with the masking tape


I'm killing time between coats of clear at the moment. Should have some full color updates later tonight.

08-08-2015, 6:04 PM
Now broadcasting in full color...








08-09-2015, 9:02 AM
So badass. Keep killin it dude.

08-09-2015, 11:12 AM

08-09-2015, 7:26 PM
nice... looks like your flake/pixie duster was jetting jammed up a bit, I don't know if you're rattle bombing or using a spray rig... but at a hose dryer to keep moisture out of the line and flake will fly out a lot better,

08-10-2015, 4:04 PM
Everything but the clear is from cans. Krylon Glitter blast and duplicolor metalcast. Wasn't going for perfection by any means. It was kind of rushed, in fact. I've just gotten tired of seeing this thing in pieces and grey primer in my dads garage. It's time to get this thing together.

08-10-2015, 6:00 PM
This bike is kooky and fun. I love it!

08-11-2015, 6:49 AM
So badasssss

08-11-2015, 10:28 PM
Too cool!

08-12-2015, 1:49 AM
Love what your doing here. Cant wait to see it done.

08-12-2015, 3:26 AM
This thing is so badass. I do the same thing with small bikes. My harley buddies talk shit, but im the only one who hears "nice bike" when we ride, while theyre rocking stock. So it pays for itself in a way lol.

Fuckin killer scoot, btw.

09-04-2015, 2:27 PM
Any updates?

09-04-2015, 5:00 PM
Seriously man, you're killing it! This is so gnarly!

09-04-2015, 6:56 PM
Thanks for the props guys. Good motivation to get to the garage.
I've made some good progress this past week. She's a roller and I actually got the motor bolted up today... Sadly, I didn't get to take any pics. Useless, I know.

My plan is to get this thing together enough to be able to show it at Rice-o-rama: A week from Sunday. It won't be 100%, but I should be able to run it. I still need to fab some pegs, paint some odds and ends, upholster the seat, and run some wires.

09-08-2015, 6:20 PM
Well, I've only got a few more nights to work on the bike before Rice-O-rama. Seems doubtful, but I'm tryin.
Snapped off a couple pics with a shitty camera tonight:

Started fabricating some foot pegs. They'll bolt up to the bottom of the engine, like stock.


I got my tail lights bolted up. No light wiring happening before the show.


and here's an overall shot


To do:
Finish pegs
paint odds and ends
stitch seat
setup shifter & linkages
wire ignition & battery
hookup rear brakes
make side covers

09-09-2015, 12:45 AM
Awesome bike and the paint came out great for rattle cans!

09-09-2015, 7:16 AM
nice inspiration for the next gen of kiddies coming up... looking to go legal by chopping what theyve got. Enjoying the thread mate.

09-15-2015, 5:38 PM
Well, I didn't get it finished, but I got it together enough to show at rice o rama. pretty good time. wish I had more $$ for the swap meet. Lots of rad bikes.




09-15-2015, 8:01 PM
Sick!!! I dig it.

I have a Honda c70 i'll be doing a chop on soon. This is definitely inspiration!

09-21-2015, 6:59 PM
Super bitchin'!!!

09-25-2016, 5:53 PM
I finally got some momentum going on this thing again. Hoping to get it on the road in the next 2 weeks.
Ran some stainless fuel lines, got a velocity stack for my downdraft carb, stitched up a seat cover, started on my wooden sidecovers.


09-25-2016, 11:50 PM
Damn man its good to see this lil beast near completion