Old School Chopper Frame Fabrication - Knucklebuster

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Figure 16 The next task is to form the fish-mouths in the wishbones that will accept the frames top tube. Part 3 Most hole saw based tubing notchers can’t be adjusted to make angled cuts as shallow as the 26 degree notches required for the connection of the wishbones to the top tube. The alternatives at this point are to use an end mill, set the tubes in an adjustable vice on the drill press and mount a hole saw in the chuck or use a miter template and cut the notches with a die grinder. I’ve been doing it so long with a grinder that for me at least this seems to be the easiest and fastest way to make the cuts. Regardless of the method used it is always a good idea to have alignment lines on all your tubing sections. Depending upon the particular application you might just need control lines on the front and back faces of the tube or front and back plus each side face. In figure 17 below we’ve used an indelible marker to scribe the control lines where the toe and heel of the wishbone fishmouth cut will be made.
Figure 17 There is a corresponding longitudinal control line 180 degrees around the tube on the reverse side. Using a tube mitering computer program we generate a printed template for a 26 degree connection angle in 1.25” tubing. Cut the template and scotch tape it together at the seam leaving it just loose enough to slip down over the tube end. Figure 18
Page 1 and 2: Old School Chopper Frame Fabricatio
Page 3 and 4: 1. Steering head. Also called the s
Page 5 and 6: Figure Error! Bookmark not defined.
Page 11 and 12: Figure 11 This cross member sets th
Page 15: Figure 15 Figure 15 shows the end r
Page 19 and 20: Figure 19 I call this area of the f
Page 21 and 22: Figure 23 The slope angle of the 'r
Page 23 and 24: In Figure 3 we can see the two tube
Page 25 and 26: Figure 1 shows the basic components
Page 27 and 28: an eighth of an inch clearance betw
Page 29 and 30: Figure 6 In Figure 6 we've deepened
Page 31 and 32: Figure 2 if you look closely you ca
Page 33 and 34: angle finder. It explains is easy t
Page 35 and 36: Figure 6 In this shot I've propped-
Page 37 and 38: In case you're interested I messed
Page 39 and 40: Figure 3 Figure 3 depicts a plate t
Page 41 and 42: Figure 7 Figure 7 is another 'boxed
Page 43 and 44: Regardless of the style or type of
Page 45 and 46: Figure 13 At this point all you nee
Page 47 and 48: Figure 1 You'll no doubt realize th
Page 49 and 50: Figure 4 Actually the plate will be
Page 51 and 52: If you're building a frame without
Page 53 and 54: Figure 5 Now that the plates are in
Page 55 and 56: Figure 2 Clean the notch up slightl
Page 57 and 58: Figure 5 The frame in Figure 5 is o
Page 59 and 60: Figure 7 The tube in Figure 7 above
Page 62 and 63: We'll now begin doing the detail wo
Page 64 and 65: The charge has been removed from th
Page 66 and 67:
Some people have reported problems
Page 68 and 69:
Steering Necks For some unexplained
Page 70:
Figure Error! Bookmark not defined.
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Old School Chopper Frame Fabrication - Knucklebuster

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