Chopper Assembly - Assemble it for
the first ride, make sure all parts
fit before painting
Engine Mount/Frame Gusset : The engine
was placed into the frame for proper
alignment of the upper motor mount.
A small piece of tubing is cut and
bolt is welded to the back and attached
to the engine mount. Tubing is then
cut to connect the mount to the frame
and it spot welded into place.
The neck brace was then cut and spot
welded into place.
Tank Mount: The Fuel Tank is set
in place using precision alignments
tools(drywall screws). With the tank
centered, the mounts were spot welded
to the backbone. The rear mount was
welded first, followed by the front
Voltage Regulator Mount: The stock
voltage regulator and master cylinder
bracket was saved and place onto the
new downtubes. The downtube welds
have also been grinded in this photo,
a polyester glazing putty will be
used before painting.
Ignition Switch Mount: The ignition
switch is mounted under the tank and
is attached to the upper engine mount.
A 1.5in tube was cut to house the
new switch and a endcap was added.
Sheet metal is then added to complete
Tank Sheet Metal: Sheet metal is
added under the tank to hide the wire
harness and provide a clean look.
Using card board templates first,
the sheet metal is then cut and welded
into place. 3 different sections of
metal are used, after the polyester
is applied, it will look like one
Cosmetic Tank Extension: The WCC
tank ends just before where the stock
seat pan meets the frame, our seat
location has been moved back and lowered.
To fill this gap, a "fake" tank Extension
is added by welding in steel rod to
create a point. This will be filled
with Polyester and sanded to match
the tank contour.
Swing Arm, Wheel, and Fender: A custom
2" tube was added to the swing arm
mount to hide the exposed swing arm
bearing extension that was added previously.
The rear wheel was them mounted and
the fender was bolted on.
Don't forget to add the drive belt...
Trees, Fork Tubes, and Wheel: The
7* triple tress were installed and
the 10" over fork tubes were then
slid into place. The front wheel was
Engine, Trans and Fuel Tank: The
Engine and Transmission were set into
place. The Primary Drive Case was
added. The Engine to Transmission
are now bolted in place with the alignment
set. The tank was then set inplace.
Tail Light, Shifter Linkage, Head
Light and Air Intake: As each custom
component is added, each nut and bolt
are carefully selected. These will
be marked for painting or chrome during
the disassembly of the hot mock up.
Wiring, and Throttle Cable: All the
wires in the handle bars are pulled
through to hide them (blinkers, horn,
low/high beam, run and start) and
placed under the tank. The throttle
linkage is also run under the tank
and is exposed at the ignition switch.
Front and Rear Brakes: The front
and rear brake calipers are attached.
A custom 54" line is added to front
to accommodate the frame stretch.
The Stock Line is used for the rear.
Starter, Jack Shaft, and Primary
Drive: Installed the starter and jack
shaft. Added the new 1 7/16" compensation
sprocket for the wide tire and installed
the clutch and drive chain as an assembly.
Then tightened the compensation bolt
Exhaust Preparation and Install:
Before the Samson Big Guns II exhaust
pipes are installed, they are treated
with BlueShield to prevent blueing.
This will cause a carbon layer to
form and insulate the metal from some
of the heat. This layer was applied
twice, you can see the pipes hanging
Oil Tank, Ignition Coil, Pugs Wires
and Horn: The oil tank is placed under
the seat. A minor cut was needed for
the starter wiring, sense the the
started was moved 1.5" A Dyna Performance
coil and Ignition system was installed
using the stock bracket. The horn
bracket was modified (no longer need
the vacuum advance) and the horn was
Completed Wire-Harness: After all
the wires were routed through the
frame and all the components installed,
the wire-harness was labeled and documented
for future reference. Click on the
diagram below for a detailed drawing.
Completion of Hot Mock Up: The hot
mock up phase is now completed. All
parts have been installed and properly
aligned. This was the most difficult
phase so for, each nut and bolt was
cut for a perfect fit. Custom brackets,
sheet metal and wiring... We are now
ready for a test drive!
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