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  1. #1
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    Default First chopper build

    So basically my neighbor/family friend told me I should document the build process of this bike so I could show future employers that I don't sit around and pick my nose all day. Well regardless of whether I'll use it for that purpose or not, I liked the idea. I've already started building the bike, so I'll try to piece together everything I've got so far.

    Just some quick background: I bought this bike right when I turned 18 from some old lady in NH that couldn't ride it anymore for $2300. I rode it mostly stock (I swapped out some parts) over the summer season and then tucked it away when I left for school. While I was at school my sister kinda sorta totaled my car. When I got the money for the car back I decided to build the bike because I didn't really want a car anymore and I had wanted a to build I bike for a while. My dad owns an automotive repair shop, so I've always had the tools I need. I have some experience with cars just from general goofing around with my friends and I've always liked working with my hands.



    When I first bought the bike, its a 1995 sporty 1200
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    After I had put a couple parts on it, (Drag pipes, Banana seat, Z bars + risers, forward controls, Tank lift and ignition relocation, coil pack relocation)
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    So I started the build over my winter vacation, the tear down of the bike took me about 2 days and approximately 3 steak and cheese subs
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    This picture is the only one that I have of the tear down (I didn't think I would be documenting)
    Along with the teardown I also stripped the wiring harness down to the bare essentials.

    So I went with the Haifley bros hardtail, but I actually didn't end up receiving it until a week after my winter break ended. So fast forward a month or so.
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    Me measuring the cuts I need to make
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    Last edited by ScubaSheen; 02-18-2017 at 9:38 AM.

  2. #2
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    Default

    So for whatever reason it only let me put 5 images in each post, so this is continued:

    So I lined up the hardtail with the motor and tacked it into place with my crappy flux core welder

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    then I went down to my dads shop and did the rest with the gas MIG welder they had down there

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    I got a king queen seat from haifley thats awesome, so I just wanted to put it on and see how it looks

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    Last edited by ScubaSheen; 02-17-2017 at 11:38 PM.

  3. #3
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    This is another angle of the seat on the frame

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    So I wanted to go with a 6 over front end, but before I bought tubes, to check the stance of the bike I measured and pulled the fork tubes so it would feel like 6 overs

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    Last edited by ScubaSheen; 02-17-2017 at 11:40 PM.

  4. #4
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    For the bars, I drew some dimensions I thought I would like in solid works

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    Last edited by ScubaSheen; 02-17-2017 at 11:34 PM.

  5. #5
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    I sent the dimensions to a fab company thats located out of Worcester MA called The eazy co. The guys are cool and they do good work too. The bars they bent are a little different than the ones I came up with, but they are much more functional than mine

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    these are the bars they bent with 2in risers welded on
    Last edited by ScubaSheen; 02-17-2017 at 11:54 PM.

  6. #6
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    That basically brings it up to speed, I bought a 33.4mm front end off some guy on instagram and I have a load of parts I have been stocking up that I can't wait to put on. I'm running real low on cash so hopefully I can sell some of the old parts to get some of my money back. I hope to finish this project before bike week this year.

    Next post hopefully I can get a better camera and include more detail in each step. Until next time.
    Last edited by ScubaSheen; 02-18-2017 at 10:00 AM.

  7. #7
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    hell yeah, looking good man. heads up about the 33.4 mm front end, you'll need a 1" stem to work with your current cups n bearings, so if you have a big twin 33.4mm from end you're good to go, but you may need to replace the lower triple tree to suit this.

  8. #8
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    Quote Originally Posted by FatChibs View Post
    hell yeah, looking good man. heads up about the 33.4 mm front end, you'll need a 1" stem to work with your current cups n bearings, so if you have a big twin 33.4mm from end you're good to go, but you may need to replace the lower triple tree to suit this.
    Thanks for the heads up, The front end does have a 1" stem so I should be all set

  9. #9
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    Good job, keep at it.
    If you pay some one to do "Bars" for example, stick to your guns. Those bars look like stock bars.
    But all in all, looking good.

  10. #10
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    Quote Originally Posted by BuddhahoodVato View Post
    Good job, keep at it.
    If you pay some one to do "Bars" for example, stick to your guns. Those bars look like stock bars.
    But all in all, looking good.
    I failed to mention that this was the design that I gave them the thumbs up to do, Me and John (employee at easy co) spoke back and forth about the details several times. One of his ideas was to modify an existing set of bars that they produced to my liking. The solidworks design I did was kinda just what popped into my head, if I had asked John to build the same bars I had put together in solidworks, I'm sure he would have.
    Last edited by ScubaSheen; 02-18-2017 at 4:02 PM.

  11. #11
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    So I'm home from school for the long weekend and decided to work on the frame a little bit

    I chopped off the stem lock

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    This evo frame had a little screw in the neck, I'd imagine for a hanger of some sort. Not needed anymore.

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    (I had already used a grinder to get it down)

    and then I plug welded on top, and grinded it down to make it disappear

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    Last edited by ScubaSheen; 02-18-2017 at 4:05 PM.

  12. #12
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    I also wanted to get rid of the tank mounting holes in the neck gusset because I'm running a frisco style tank. So I cut them off and grinded them down.

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    And to fill the hole, I cleaned off some crusty thread I found under the table in the shop and welded over it.

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    Last edited by ScubaSheen; 02-18-2017 at 4:05 PM.

  13. #13
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    Quote Originally Posted by ScubaSheen View Post
    So I'm home from school for the long weekend and decided to work on the frame a little bit

    I chopped off the stem lock

    Click image for larger version. 

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    This evo frame had a little screw in the neck, I'd imagine for a hanger of some sort. Not needed anymore.

    Click image for larger version. 

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    (I had already used a grinder to get it down)

    and then I plug welded on top, and grinded it down to make it disappear

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    That screw in the neck was a zerk fitting so you could grease your stem bearings. Project is looking good though!

  14. #14
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    Quote Originally Posted by rextec View Post
    That screw in the neck was a zerk fitting so you could grease your stem bearings. Project is looking good though!
    I done goofed

  15. #15
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    'scribed.

  16. #16

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    Quote Originally Posted by ScubaSheen View Post
    I done goofed
    Whoops. Good to know. I was wondering what it was on my frame.

  17. #17
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    I totally have a set of bars that look like you designed Haha
    Stoked on your build. I'll be watching. Just started my build too.

  18. #18
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    Quote Originally Posted by hellamopeds View Post
    I totally have a set of bars that look like you designed Haha
    Stoked on your build. I'll be watching. Just started my build too.
    appreciate it!

  19. #19
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    So I'm home from school for spring break and I'm gonna try and bust some stuff out on the bike. I don't have enough money to finish it right now, but I'm damn close. I need: 6 over 33.4mm tubes, 21in drum front wheel + tire, and some funky pipes.

    Today I fit up the gas tank and welded the bungs in:

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    I kinda grinded the bungs down like an idiot, but whatever nobodys gonna see em and there in

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  20. #20
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    I also realized with the new front end I don't need the ol fork lock on the headtube. so ITS GOTTA GO

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    Heres the new front end, she needs a little love. But shes gonna do fine.

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    Also, I know that with the 39mm front ends, when you put longer tubes on you would also make a spacer so that the spring has the same preload and stuff. Is the same method used on the 33.4mm front ends? Might be a dumb question, but better safe than sorry. Thanks!

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