Custom Build Chopper (The Ultimate Cruising Machine)

[Xulfiqar]

I hope you are not planning to run this with that cheap n soft bolt holding the drive sprocket in place.

[vickytulla]

he tried and got the chain snaped... machinist advised two options

1 - Create a grove in front of sprocket on shaft and use a Lock (cirClip)

2 - or bore a hole at where that Bolt is across the shaft and use a hard steel bolt to lock the sprocket.

spent a whole weekend testing that ride... Good work by Denter I must say ... completely balanced modification, every thing just fits in nicely.

I am not liking the handle for sure..

@angel82 u posted the whole weekend today ... lol chain ka kiya bana ar par sorakh ya Lock ?

I hope you are not planning to run this with that cheap n soft bolt holding the drive sprocket in place.

[vickytulla]

Just giving you rough ideas. Wo chopper hi kya jo mute ho chopper suit with loud exhausts but some exhaust come with db killers to reduce the noise

I would agree on this one with shafi! coz mut ho na ho cruiser k singature not chahy bohut loud na bhi ho mager aik distinct noise signature hota hai and u would notice it in you tube videos too... wo inshAllah zuroor banayein gy..

[vickytulla]

here it is lil bro of ur chopper

damn this thing is hot..

[vickytulla]

broken links in this post... u must clear ur cache of browser ..

So here comes the final product by the denter.

1- Radiator mounts made and fitted
2- Silencer bends made and fitted
3- Broken foot rest repaired.
4- Gear lever made and fitted

All of his checklist is completed. Now time to come back to mechanic's garage.

@vickytulla inspecting the final outcome and we think everything is according to the requirement. or i must say exceeding our expectation.

So the denter has done an awesome job. I hope the chopper will keep on rolling like this.

[hidalgo]

nah man , ape bars are fun to ride trust me

[Xulfiqar]

he tried and got the chain snaped... machinist advised two options

1 - Create a grove in front of sprocket on shaft and use a Lock (cirClip)

2 - or bore a hole at where that Bolt is across the shaft and use a hard steel bolt to lock the sprocket.

spent a whole weekend testing that ride... Good work by Denter I must say ... completely balanced modification, every thing just fits in nicely.

I am not liking the handle for sure..

@angel82 u posted the whole weekend today ... lol chain ka kiya bana ar par sorakh ya Lock ?

The bolt you are showing is wrong, you need an 8.8 grub screw with socket drive - and threadlocked in place. The output shaft shocks the drive sprocket a lot.

[vickytulla]

nah man , ape bars are fun to ride trust me

Indeed but on tour they are going to kill him

The bolt you are showing is wrong, you need an 8.8 grub screw with socket drive - and threadlocked in place. The output shaft shocks the drive sprocket a lot.

Indeed! but I still doubt that even a grub screw will snap too as I think due to shocks on shaft on instant clutch releases I am more leaned towards a Lock circlip type it will gie room to sprocket to stay lose and still not get out of the shaft just like honda bikes there front sprocket is locked and alway lose and can be shaked by hand even... ... but last day we decided to discuss this with few more machinists and have there point of view and then decide...

[angel82]

The bolt you are showing is wrong, you need an 8.8 grub screw with socket drive - and threadlocked in place. The output shaft shocks the drive sprocket a lot.

Its an honor and very encouraging to get an advice from PW Living Legend. This bolt is temp basis and we already have it in to do list. I'll keep you advice in mind and do accordingly.

Indeed but on tour they are going to kill him

nah man , ape bars are fun to ride trust me

Haha theek hai aise ride kerte hoye isb ajaonga phir malishye ka intezam aap rakhna @hidalgo

[angel82]

Another reason for building a chopper

[vickytulla]

@dr.omair .. indian the fav. ride ...

Another reason for building a chopper

[angel82]

Time for Electric work:

Now its time to take the bike to the electrician so its wiring and connections can be completed. Can't wait to get it completed but still the process is slow due to nitty gritty. Even though the wire harness was completed with the frame but still it takes time to compile everything back.




CDI, Self Start Relay Installed.

Temporary HeadLight

It took 2 days to complete and on 2nd night when we about to finish the ultimate delima happened the light gone So my car start to provide emergency light service.

Looks like its evening but it 11 pm at night

Fitting Radiator Fan

[Xulfiqar]

Indeed but on tour they are going to kill him

Indeed! but I still doubt that even a grub screw will snap too as I think due to shocks on shaft on instant clutch releases I am more leaned towards a Lock circlip type it will gie room to sprocket to stay lose and still not get out of the shaft just like honda bikes there front sprocket is locked and alway lose and can be shaked by hand even... ... but last day we decided to discuss this with few more machinists and have there point of view and then decide...

the small loose sprocket on the Honda machines is held in place by a collar and very tight screws on that collar - factory manual tells you to threadlock those screws.

The grub screw will not bear any radial load as the entire thing is gear tooth engagement already, the grub will simply hold it in place, a circlip will also help if you fancy. You can also choose to mill the shaft and provide some threads (e.g. Yam DT, RX, YB etc) and lock provide a strong nut to keep it in place.

I like the circlip idea too but it depends on the quality of the mill work.

[vickytulla]

yea ... most machinists are also in favor of Grub screw ... out of bunch of good machinist only one took challenge of drilling a hole in shaft for the screw... other asked for de-assembling the engine which was totally out of the list.. bike is with the machinist a day back no idea what are the updates ..
@angel82 bro kya bana ..

the small loose sprocket on the Honda machines is held in place by a collar and very tight screws on that collar - factory manual tells you to threadlock those screws.

The grub screw will not bear any radial load as the entire thing is gear tooth engagement already, the grub will simply hold it in place, a circlip will also help if you fancy. You can also choose to mill the shaft and provide some threads (e.g. Yam DT, RX, YB etc) and lock provide a strong nut to keep it in place.

I like the circlip idea too but it depends on the quality of the mill work.

[hidalgo]

need input from you guys here https://www.pakwheels.com/forums/bikes-3-wheelers/240386-swapping-2stroke-frame-4s-motor

[Xulfiqar]

yea ... most machinists are also in favor of Grub screw ... out of bunch of good machinist only one took challenge of drilling a hole in shaft for the screw... other asked for de-assembling the engine which was totally out of the list.. bike is with the machinist a day back no idea what are the updates ..
@angel82 bro kya bana ..

the machinists who want the disassembled shaft obviously do not have skill - a pilot bushing and centering spigot and an offset drill can make quick work of this job.

[angel82]

yea ... most machinists are also in favor of Grub screw ... out of bunch of good machinist only one took challenge of drilling a hole in shaft for the screw... other asked for de-assembling the engine which was totally out of the list.. bike is with the machinist a day back no idea what are the updates ..
@angel82 bro kya bana ..

Kya bana? you mean Update? yes i have a big update. Allah blessed me with a Baby Boy Shukar Alhamdulillah hehe

the machinists who want the disassembled shaft obviously do not have skill - a pilot bushing and centering spigot and an offset drill can make quick work of this job.

Sprocket work has been done as recommended by @Xulfiqar. Drilled then put Grub Screw its perfectly fit now not lose at all. I'll update pix soon. Thanks for advice keep them coming.

[angel82]

His First Flight:

So the time came where we were able to take a test ride. First we got stuck the chain was not working properly on sprocket and after moving some feet it slipped out of the rear sprocket. My mechanic called a denter he gave the verdict that front and rear sprockets are not in alignment. I was like but then @vickytulla came like a savior, checked it and then we found out that the chain was old and sprockets were new so chain was not griping sprocket properly. We purchased 2 DID Chains and combined them together and wolla it worked

Waqar bhai took a test ride and he will tell you how good the response it gave, The Torque, The Acceleration, The Speed all were awesome. I was on my RP and he was on cruiser. I consumed my 5th gear and he was only at 2 :D. and he was at 80 i guess but not sure because we were pretty excited The fun could go on and on but cruiser didn't have proper breaks so we did it under controlled. There wasn't any vibration in the engine because of its design. Most of the vibration gets dump in the ground. Then i took a test ride and it was awesome. Can't describe in words.

We totally forgot to take pictures due to excitement

[Shafin619]

His First Flight:

So the time came where we were able to take a test ride. First we got stuck the chain was not working properly on sprocket and after moving some feet it slipped out of the rear sprocket. My mechanic called a denter he gave the verdict that front and rear sprockets are not in alignment. I was like but then @vickytulla came like a savior, checked it and then we found out that the chain was old and sprockets were new so chain was not griping sprocket properly. We purchased 2 DID Chains and combined them together and wolla it worked

Waqar bhai took a test ride and he will tell you how good the response it gave, The Torque, The Acceleration, The Speed all were awesome. I was on my RP and he was on cruiser. I consumed my 5th gear and he was only at 2 :D. and he was at 80 i guess but not sure because we were pretty excited The fun could go on and on but cruiser didn't have proper breaks so we did it under controlled. There wasn't any vibration in the engine because of its design. Most of the vibration gets dump in the ground. Then i took a test ride and it was awesome. Can't describe in words.

We totally forgot to take pictures due to excitement

Wish we had a person like waqar bhai in karachi

[angel82]

Wish we had a person like waqar bhai in karachi

hehe you are right. Lahore's biker heaven is blessed with baba @vickytulla