Old School Chopper Frame Fabrication - Knucklebuster

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Figure Error! Bookmark not defined. While this might seem like a simple operation it pays to stay alert when you’re knocking this little item out in the garage some late evening. I admit that on more than one occasion while under the influence of certain health beverages I have cut the fish-mouth in the top of the seat post tube backwards relative to the angle cut made in the base. What’s worse is that I welded it together and didn’t notice the problem until the next day. The slope angle on the seat post relative to a vertical line is 17 degrees. The stock angle is just a hair under 16. The extra degree of slant combined with the 19” length gives the frame room enough to house Evolution motors. In effect the top of the seat post has been moved .625” towards the rear and the backbone has been raised .625” in relation to a stock Panhead frame. I think the easiest way to build the seat post is to first make the fish-mouth cut with a hole saw mounted in a tubing notcher or by using a miter template and die grinder. The angle between the seat post and backbone is 97 degrees. If you’re using a notcher set the angle to 7 degrees and make the cut. Figure 7 shows my cheap imported tubing notcher with the seat post set up for the cut. Do not trust the protractor built into your notcher. Always check the actual angle with a good accurate angle finder. In this picture as we set the tube up for the cut our little yellow angle finder said we were right on 7 degrees but the factory supplied dial on the face of the notcher read 5 degrees. Had we turned the tube to the 7-degree mark on the notcher we would have actually cut a 9-degree angle.
Figure Error! Bookmark not defined. In case you’re wondering I don’t bolt the notcher to a bench since no matter how I installed it there never seemed to be enough room for long tubes so when I’m ready to make the cut I put the whole mess on the floor and stand on the mounting tab as I’m running the drill. On the rare occasion that I do bolt it down I like it to be in a horizontal position. Figure 8 is pretty fuzzy but I think you can see how rough of a cut these cheap notchers make. Figure Error! Bookmark not defined.
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 7: Figure Error! Bookmark not defined.
Page 11 and 12: Figure 11 This cross member sets th
Page 13 and 14: Figure Error! Bookmark not defined.
Page 15 and 16: Figure 15 Figure 15 shows the end r
Page 17 and 18: Figure 17 There is a corresponding
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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