Old School Chopper Frame Fabrication - Knucklebuster

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ends being made in the lower rails where they sweep up into the axle adjusters. This is especially true if you're not using a welding jig. Figure Error! Bookmark not defined. These ramp angles as mentioned earlier are fairly critical and after you've made the bends stand the tubes up on some surface that is absolutely flat and using an angle finder check to make sure that the tube geometry is as it should be. Figure 22 The slope angle of the down-tube should be ten degrees off vertical.
Figure 23 The slope angle of the 'ramp' should be forty degrees above horizontal (fifty degrees off vertical) and the length of the tangent piece of straight tube should be four inches. If you're 'off' by thirty minutes, (one half of a degree), or more, put those tubes in the scrap bin and try starting over again. In all seriousness though you can be off by as much as one degree either way but if the bend is to tight you'll need to move the lower rails forward slightly so the downtubes don't hit the motor's front cylinder head. Part five Once the forward bends are made in the lower rails its time to fit these into the upper section of the frame we've already made. Specifically at this point we want to cut the tube miters where the uppermost portion of the down tube attaches to the backbone. The frames I build are based upon the old original Harley-Davidson frame design where the down tubes attach to the frame backbone and not to the steering neck tube as you'll see on a lot of modern choppers. Figure 1 illustrates a stock Harley neck and even though this particular neck is a casting the same design principal applies to a tube type neck.
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 and 16: Figure 15 Figure 15 shows the end r
Page 17 and 18: Figure 17 There is a corresponding
Page 19: Figure 19 I call this area of the f
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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