Shovel Chopper Build
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Road Captain
Joined: Jan 2013
Posts: 546
Likes: 606
From: Out West
I have to integrate my Brembo caliper with the forks to get the proper location on my 320mm disc.
I start by using double-back tape on the brake pads, and some inserts so that it holds snug on the disc so that everything can be located.
The last pic shows my target swept area (pad to disc contact) once I get everything done.
Here I am locating my caliper. This is where making those inserts really helps. I can position the caliper easily, and it doesn't slide around.
I didn't actually use the wire as a standoff between the caliper and the outer edge of the disc, but I just took that pic so an alternate positioning method is shown. You don't want contact there obviously.
I needed to get my numbers to have the caliper mate with the fork bosses.
I turned some precision "buttons" that drop into my fastener holes. I just made them all 0.700" in diameter, but any diameter will do as long as they are all the same.
Once I get everything set up, I create a 90 degree angle from the bosses on the fork to one boss on the caliper. This only leaves any real math for locating one boss.
This was an easy tie-in, I have had some really complicated ones.
Got my numbers, and made a mockup plate. I punched the holes in the mill, then just took a bandsaw to the outside so it fits.
Got lucky! Perfect fit. I then know my numbers are good, so I designed and made my plate to mate the caliper to the forks.
What is fun about this, is that I can run any wheel/brake/caliper combination I want.
All tied in. I will polish everything and shave the legs of course, but you get the idea.
Used stainless steel tubing to make the bars. Bending the 304 stainless is a pain. As I said before, this bike will have no chrome, so polished stainless is what I am after.
I used some string as a reference so that the bend complements the backbone on the frame, and I can really see that everything is totally even. The bars are left long, and will be narrowed later.
I have some chopping to do on the frame yet, but that comes a little later.
Last edited by ChickinOnaChain; May 15, 2018 at 11:07 AM.
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Road Captain
Joined: Jan 2013
Posts: 546
Likes: 606
From: Out West
Making my clutch outer pack. I just clamped it in an available vise, so that's why it's hanging off the side in the mill. No biggie, it all comes out the same.
Finished outer pack. It's not polished yet, but you get the idea. It's actually very compact and lightweight, the picture doesn't do it justice.
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Thread Starter
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Road Captain
Joined: Jan 2013
Posts: 546
Likes: 606
From: Out West
Got the best transmission money can buy, it's a Baker 6 speed. Since this is going to be a kick-only chopper, that starter ear has got to go!
I just made a plate so that I could clamp it in the mill, took a hacksaw to get rid of the steel dowel and went to town. The point of no return.
Sculpted everything clean to mate with my bearing support plate. Nope! Didn't make the support plate, it's a slightly modified available product.
Indian Larry was the King of Choppers in my opinion, and his philosophy was that you needed at least one spoked wheel.
I got a Marchesini forged magnesium race wheel and modified it to go with my build. I am running a 180 on the rear. Not too fat, not too skinny.
It weighs about zilch, and has that gorgeous silver/gray that only polished mag gets. Two guys can easily lift this bike, it's super light as Choppers go.
Thanks to all so far that are following the thread. Much more to come.
Last edited by ChickinOnaChain; May 15, 2018 at 11:08 AM.
