The Build Log:
Well as has become my custom I start with the wheel,
I wanted a rounded motorcycle tire for my chop, but I didn't
want to pay $200 for a tire, a search at a cycle salvage
yard turned up a Dunlop 180/55/17, good enough I thought and
only $50 barely used. Problem was the "17in" part, I knew I was
going to use a car rim rather than a cycle rim, the larger rims
for these type of tires are alloy, not suitable for garage hacking
unless your garage has a machine shop. But I wish I had been able
to find a 15 or even a 16in tire instead, finding a rim would have
been a lot easier (and cheaper), cars rims of many different widths are
available in 14,15, and 16in sizes. So an arguous search began for a 17
in rim, turns out the new Chysler and Buick SUV's often come with
stock 17in steel wheels, the problem was they arn't readily available
at the local junk yard for $5 and $10, the local dealers wanted $100
to order one. Well when you don't have a lot of money you find ways to
save money, this wheel has been on the Buicks since 2005, where do these
wheels go when their ouners decide to buy some serious wheels for their ride?
A check at my local Les Schwab tire dealer says "well they keep them, you
know for chains, they don't want to tear up their nice rims don't you know."
No i didn't know that lady, and it made sense but I still wasn't buying it,
a check at a little hipper tire store introduces me to a new phrase,
"dealer take-offs".. ah tell me more, well it turns out a couple of companys
purchase these old wheels from dealers and tire shops and resell them themselfs,
a call and a short drive and I have my 17in rim for $45, still more than
I wanted to pay but cheaper than $100.
Ok so rim and tire in hand, I wanted to do a solid spoke thing this time,
a local steel yard burned me a 15in disk with a 1 & 1/2in hole in the center
out of 1/4in steel for $20.
I drew my pattern on and cut it out, I used a simple pattern to accomadate
my simple tools (saws-all and grinder :) I spaced the new spokes in the
center of the wheel, using the existing center as a guide, this was hard,
I cut the tacks out and redid it a couple times trying to get it just right.
When I was happy with the centering I started pounding the old center out,
(i had ground down the welds on the center before hand).
OK so after cleaning up the rim and some extra zip disking on the spokes
I'm ready to start building my hub, this wheel is 8in wide, my 1 & 1/2in (O.D.)
tube is 9in long, I'm using a 14in axle. my doner hub has freewheel threads
on both sides for my gear and a disc brake, I only had to chop it in half
(the ends will be inside the tube and not seen anyway). I'm using 2 pieces
of 2in (I.D., one on each side, about 2 & 3/8 O.D.) pipe with washers tacked
on (they have 1 & 1/2 center holes and fit perfectly).
These larger pipes will add strength to the hub and give it that cycle look.
After tacking the parts in place I used my shopping cart jig to give the wheel
a spin and see how true it was, it was also useful for cleaning up the welds.
Here's the wheel after mounting the tire, it's certainly no Harley wheel
but a little paint, a little polish and it'll do, it'll do :~)
On to the bike itself ~
Saturday 02/10/07
Well I incorporated my doner bikes front shocks and forks onto
the bike today, at least this way the front disk brake will be right.
I'll probably build my oun support on the back side and remove that front one.
Sunday 02/11/07
Had about 3 hrs to work on it today, got some tubing going :~)
Saturday 02/17/07
Built a set of handlebars, misc did a mock up,
Most of it is just tacked together right now lol
Sunday 02/18/07
Cut the forks down a little, capped them.
Built the tranny, did a bunch of the welding.
Saturday 02/24/07
Got most the welding done, strung the chain.
Should be able to do a test ride tommorrow.
Sunday 02/25/07
Well maiden voyage a success, took a
nice long ride no problems.
Well back to work, need to get the rear fender
and some lights mounted before painting. I've
decided to call it "The Enterprise", I'm painting
it stainless steel and black (both epoxys).
Saturday-Sunday 03/03-03/04/07
Mostly just preping for paint this weekend,
did add a Star Trek insignia to the frame,
got a more comfortable seat, (it's a Bontrager
that uses memory foam) worked on the brake
lines and some cosmetic things like the tranny.
Really having trouble finding a true "rounded"
fender, guess I'll have to manufacture one out
of something because I can't afford a Harley
fender lol
Saturday-Sunday 03/10-03/11/07
Got the fender installed, would have liked a more
"rounded" fender, settled for a trailer fender, this
one was $22. Built some misc brackets for the lights.
Got a sun break Sunday and shot the cover paint, even
coated the inner fender with undercoat.
Well a week for the paint to cure and we'll be set :~)
Saturday-Sunday 03/17-03/18/07
Well got the bike put together and made it down
to Eugene for a St Pattys day fun ride Saturday,
check out some pics here at Chopperbicycle.net
I'll try to get some better pics of the bike this week.
