We also build a wide assortment of accessories including gas tanks, oil tanks, handlebars, fenders and springers to cover all the bases. Here is a rigid sportster chopper frame 250 series. Basic motorcycle geometry trail rake or castor angle steering axis inclination wheelbase. They also come in a variety of materials and shapes. The fixtures are for sale individually or can be purchased in a kit to save money and fabrication time. Lets build a motorcycle building the frame jig youtube. Whether you want to build a sport bike frame or a chopper frame, neither. Early motorcycle frames served chiefly as a mounting point for all the things that make a stack of tubing different from a motorcycle. Motorcycle kit bikes build your own chopper or bobber. Diy sidecar frame kit motorcycle sidecars, motorcycle trike. Mar 5, 20 when you get into the discussion of motorcycle frames and what to build for your next bike building project you first need to decide what kind of motorcycle you want to build. With a chop source frame jig kit you could have your motorcycle frame jig assembled in just a couple of hours.
Also attached to the frame are the fuel tank and battery. The fatigue testing was done inhouse using a test rig specifically built for this project according to the astm standard f271108 for horizontal loading. Chop source motorcycle frame jig parts fixtures chopper. A motorcycle s chassis or frame forms its skeleton. Heres 9 minutes of my 99 minute tutorial on the fundamentals of motorcycle design and sketching found on my gumroad account. When i started the euro spares website back in the mid 1990s i had been writing and posting a series of articles on frame design and construction to some of the email lists i was on. The purpose of a motorcycles frame is to act as a base onto which all the various components can be bolted to.
You have a bunch of parts and more will be ready in the future. The engineering process for the design of a motorcycle. It does however give you a frame of reference for what must be done to build a chopper frame. The strength of frame construction is correct design of a frame because it is the most important part that ensures safe riding. It supports the engine, provides a location for the steering and rear suspension, and supports the rider and any passenger or luggage. They have a little bit of rake, and they are slightly stretched compared to a sportster chopper frame. Front and rear swing arm design of an electric racing motorcycle. The tutorial includes a 720p mp4 av file at 99 minutes in length, related jpegs of the 3 sketches done on camera. Their design is done by bending the cold, and connect. The easiest frame to build is a traditional old school styled chopper since there arent any complicated bends or compound miters to cut so we decided to show.
Use your imagination and make a rough sketch and mention the specifications on the drawing. There is a lot tuning to be done to get the rig set up correctly. Understanding a motorcycle parts diagram learn the basic parts of a motorcycle with a simple to read diagram. How to design and construct a motorcycle engine powered race car. There is no specific guide to detect inherent weakness in a frame design, but in general any street frame built before 1970 needs work, excluding featherbed types used entirely for pleasure.
Motorcycle chassis design and modification by jeffrey diamond. These pages detail the design and build of a motorcycle sidecar. All parts are fabricated in our enumclaw, washington shop from steel. Please contact us with any questions on kit bikes or call 407 8470119. Motorcycle basics techbook by john haynes all common engine, chassis and electrical systems fully explained and illustrated. This first of the series is a one hour and thirtynine minute tutorial on researching, learning about how to layout a side view design and then designing an original electric motorcycle in side view. A motorcycle frame is a motorcycle s core structure.
May 12, 2014 understanding a motorcycle parts diagram learn the basic parts of a motorcycle with a simple to read diagram. A rough design of your paint scheme will help you plan the painting steps, so dont be afraid to make a sketch with your design drawn in. The basics new riders and potential motorcycle shoppers need to know. The frame also serves as a support for the suspension system, a. A solid model of the frame was created and a finite element analysis fea was conducted using the astm standard as a.
Topics covered include engine cycles and layouts, carburetors and fuel injection, ignition systems, clutches, gearbox, engine lubrication and cooling, wheels, tires, braking systems, suspension, steering, handling, design. There are tips on producing a proportioned design suitable for a given motorcycle, information on the legal requirements and tips on riding with a sidecar combination. In the following, the designing and manufacturing practice for an electric motorcycle is reported. Motorcycles have a frame made of steel, aluminum or an alloy. We can also sell you a rolling chassis with a quality frame. Well make a couple of lists, you knew i was going to say that and well start with the personal skills that will be usefulneeded. This is the first in a series of tutorials on designing and sketching motorcycles. Understanding motorcycle rake and trail and suspension. Feb 07, 20 the 4 most used motorcycle frames all this while, ive been pretty intrigued by the unique triangular pattern on the frame of my ktm duke 125.
Motorcycle frame theory, design, function and improvement. Conceptual design of a bicycle frame altair university. Jul 29, 2017 a rough design of your paint scheme will help you plan the painting steps, so dont be afraid to make a sketch with your design drawn in. Conversely, here is the rigid bobber design, also by custom choppers guide. Oct 06, 2016 heres 9 minutes of my 99 minute tutorial on the fundamentals of motorcycle design and sketching found on my gumroad account.
The frame consists mostly of hollow tubes and serves as a skeleton on which components like the gearbox and engine are mounted. Carbonfibre is sometimes used in expensive or custom frames. The components of this type of frame are the side members, the cross members, and the gusset plates figure 141. The following pictures illustrate a wide variety of frame jigs ranging from simple and crude homemade units to extremely complicated fully adjustable units manufactured for large chassis shops. In terms of importance, we order these three basic design parameters as follows. We addedd the background options to give your bike a cool stage, too. Dmc sidecars now has available for the hobbyist, a doityourself, you weld it, sidecar frame kit.
The skill level required is alluded to throughout this article. Motorcycle suspension systems can be very complex, and involve numerous variables such as wheelbase, weight, ride height, tire size, suspension sag. About 120 employees work in design, engineering and production, including 3 fulltime product designers and 3 engineers. What axle, hub and wheel to use and where to get it.
Now that you know what are the things you need, lets move on to the procedure of making a motorcycle frame. Shoemark, pete 2002, motorcycle basics techbook 2nd ed. The sole purpose of a motorcycle frame is to act as base, which all of the components gas tank, engine, suspension, handlebars etc can be bolted to. Motorcycle handling and chassis design the art and sciencetony foale warning important safety and legal notice. Feb 26, 2017 motorcycle basics techbook by john haynes all common engine, chassis and electrical systems fully explained and illustrated. Whether youre looking to build a chopper, a prostreet, a softail, a rigid, an slx or a drop seat. Motorcycle handling and chassis design the art and. At the front of the frame is found the steering head tube that holds the pivoting front fork, while at the rear there is a pivot point for the swingarm.
Specialized software, such as motorcycle kinematics, matlab, catia, heeds professional, and nastran are utilized. Feb 09, 2017 making a custom motorcycle frame jig using the tormach mill part 3 duration. The thesis objective is to define and establish an engineering process for the design of a modern motorcycle chassis and suspension. There are two basic methods for building the main triangle of a frame.
Ride basic comfort and handling need to be addressed through frame geometry rather than through special component choices at a later stage. Decoding the different types of motorcycle chassis tvs motor. Motorcycle handling and chassis design the art and science list of chapters. In 1977, harvey milk was elected to the san francisco board of. Motorcycle handling and chassis design the art and science. Mounting a chair frame to the bike you will want all attachment points to be solid but adjustable. Making a custom motorcycle frame jig using the tormach mill part 3 duration. In the beginning used on almost all vehicles, the ladder frame has. But if you are building a chopper, an important task in modifying the frame is changing the angle of the head pipe joint where it attaches to the top frame rail in the front frame down tube. Motorcycle chassis design and construction and other technical topics when i started the euro spares website back in the mid 1990s i had been writing and posting a series of articles on frame design and construction to some of the email lists i was on. Motorcycle frames are usually made from welded aluminium, steel, magnesium or metal alloy. Designing and manufacturing of a handmade electric. Frame finishes design layout 17 case study measurement main frame engine mounting results material swing arm.
Jan 22, 2019 imagine a motorcycle cruising down the highway at 70 mph, and the frame suddenly comes apart because of poor design or quality of workmanship or materials. This type of frame is usually used in track motorcycles allowing for the accommodation of the air filter which leads to heavier structures but that can also withstand very high loads in comparison to other frames. Old school chopper frame fabrication knucklebuster. Strength and stiffness analysis of motorcycle frame ktu epubl. Familiarity with basic hand tools is a definite requirement, as is the use of welders and tube bending tools.
How to build a motorcycle from salvaged and used parts. The theory and practice osprey, 1988 1988 file download duxidoh. All this while, ive been pretty intrigued by the unique triangular pattern on the frame of my ktm duke 125. I always wondered why it was shaped that particular way and the engineering rationale behind it. Anderson, engineer forest products laboratory forest service u. Diy sidecar frame kit motorcycle sidecars, motorcycle. How to build motorcycleengined racing cars build your own. As different motorcycles have varying design parameters such as cost, complexity, weight. If playback doesnt begin shortly, try restarting your device. A look at how to approach a frame build and why youd want to tackle a build in the first place. All the components of a motorcycle, like the suspension, wheels, fuel tank, seats, handlebars etc, are attached to this base structure which lends a motorcycle its strength and ability to handle well. We also build a wide assortment of accessories including gas tanks, oil tanks, handlebars, fenders and. Elementary aspects of road bicycle design, engineering and. The frame also keeps the wheels in line to maintain the handling of the motorcycle.
These articles began when i asked if anyone on the lists was interested in the subject. All angle of lean and toe in must be done between the chair frame and the bike frame thus at the attachment points. The engineering process focuses on the interdisciplinary fields of engineering dealing with design and structural optimization. Rolling thunder manufacturing is the leader in the custom frame building motorcycle after market. Choose a paint system assuming you dont have an air compressor for this process, your paint selection is a little limited.
Very nice book to understand the dynamics of a motorcycle. Generally, lugless frames are found on inexpensive bicycles since it is the least. Home plans, floor plans, house designs design basics. The body generally is bolted to the frame at a few points to allow for flexure of the frame and to distribute the loads to the intended loadcarrying members. Make absolutely sure that every aspect of the project has been carefully considered in detail. This is just a small sampling of custom and oneoff frames and projects weve built for our customers.
In this section we are going to construct a bicycle frame as shown below in. Motorcycle frames started looking markedly different from bicycle frames in the earliest part of the 20th century. Euro spares motorcycle chassis design and construction and. Since this guide is about using salvage parts, you can purchase a frame from a yard and make modifications. This is by no means an exhaustive guide on the building of chopper frames. Material and design optimization for an aluminum bike frame. Euro spares motorcycle chassis design and construction. This book explains how select and integrate the engine into a car as well as the design of the other aspects such as chassis, powertrain, brakes, fuel, coolant and electrics. As riders learned how much the frame contributed to the ride, handling, and performance of a motorbike, frame technology evolved right alongside other motorcycle components. As you can see, these bobber style frame designs have more of a chopper look. The side members, or rails, are the heaviest part of the frame.
With a wide assortment of accessories including oil tanks, handlebars, fender struts and a springer, all bases are covered. The first step is to draw the design you want, on a piece of paper. Design of motorcyle active chassis geometry change system 281 2 x 2 x r d k f s v zr z d k c s v r e f o o o o f r m. Motorcycle chassis design and construction and other technical topics. Generative design study setup in this lesson, well complete a generative setup by applying loads and constraints, design criteria, and setting materials for the motorcycle frame model. What do we need in our shops to attempt building a frame. We offer dozens of options allowing you to uniquely customize your bike. We provide free help with kit purchase, paid consulting if you want to get your own parts elsewhere. A motorcycle frame is a motorcycles core structure. The easiest frame to build is a traditional old school styled chopper since there arent any complicated bends or compound miters to cut so we decided to show the chassis fabrication process from a to z as we do it. Foales book is a hugely practical treatise on the subject of motorcycle chassis design and the only worthwhile one i know of other than some very technical sae papers from the 1970s on modeling and simulation of motorcycle handling.
This is the beginning and the basics of frame building apply to all types of frames, so well keep the complications to a minimum to start. The swing arm assembly is prewelded for you and comes with the pivot bearings and seals. Foales insight into the incredibly complex dynamics of motorcycle handling chassis design, and tire sorry, tony i just cant bring myself to spell it tyrechassisrider interaction comes from decades of building and riding specialty and adjustablegeometry frames to test out theories, and in more recent times, instrumenting. I think only book in the world for understanding motorcycle. Originally, automobile designs used the bodyon frame construction where a loadbearing chassis consisting of a ladder frame, the powertrain, and the suspension formed the base vehicle which then supported a nonloadbearing body. So after some research on motorcycle frame and chassis design, i learnt that there are actually only 4 frame.