Final Assembly - Time to bolt it all together
Frame Setup: With the frame and swing arm
painted, it is placed onto the lift to start
the final assembly. This will go quickly
now that all the parts and sub-assembles
have been previously installed during the
hot mock-up phase.
Triple Tree and Fork Tubes: The frame is
carefully tied to the lift table and the
7* rake triple tree is installed into the
frame neck. The fork tube assembly is then
slid up into the tree. Masking tape is placed
on the tree to prevent scratching the new
Front Wheel: The front wheel is installed
and is placed into into the bike vice.
Swing Arm: The swing arm is now attached
to the frame (don't forget the belt). A
chrome splash guard is attached to the front
of the swing arm.
Engine and Transmission Install: The lift
is dropped to floor. Masking tape and bubble
wrap is place onto the frame where the engine
and transmission might bump into. The engine
is carefully placed into the frame followed
by the transmission and transmission plate.
Rear Wheel: The rear wheel and air ride
suspension is installed and aligned to the
transmission. The axle covers are placed
over the end of the swing arm and the license
plate is attached to the axle.
Primary Drive/Starter/Oil Pan: The clutch,
compensation sprocket and drive is installed.
The starter and oil pan are placed in and
the oil lines are connected.
Handle Bars and Controls: The handle bars
are attached to the tress. All the cabling
was connected together from the hot mock
up, this makes the assembly very fast. The
front brake is attached to the wheel, clutch
line is attached and throttle cables are
Sheet Metal: The front fender, rear fender
and tank are attached to the bike. Man....
Its looking really nice. The cosmetic tank
extension look awesome.
Wire Harness: With the rear fender attached,
we can add the wire harness. The fuze panel
is built into the fender, the is basically
no room for any electronics on a chopper...
Seat: We attached the seat and take it
off the lift. Roll it out into the driveway,
add about 1 gal of gas... Done... She fires
right up !!!
Completion of the Final Assembly: The bike
has come along way over the last 19 months.
This has been one of the most satisfying
engineering projects that I have ever worked
on no time tables and freedom to create.
Its been an overall great learning experience.
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