Motorcycle kit bikes build your own chopper or bobber. Chop source motorcycle frame jig parts fixtures chopper. Feb 26, 2017 motorcycle basics techbook by john haynes all common engine, chassis and electrical systems fully explained and illustrated. In the following, the designing and manufacturing practice for an electric motorcycle is reported. Decoding the different types of motorcycle chassis tvs motor. Rolling thunder manufacturing is the leader in the custom frame building motorcycle after market. The first step is to draw the design you want, on a piece of paper. Familiarity with basic hand tools is a definite requirement, as is the use of welders and tube bending tools. The theory and practice osprey, 1988 1988 file download duxidoh. Motorcycle frames are usually made from welded aluminium, steel, magnesium or metal alloy. We can also sell you a rolling chassis with a quality frame. The engineering process for the design of a motorcycle.
Since this guide is about using salvage parts, you can purchase a frame from a yard and make modifications. It does however give you a frame of reference for what must be done to build a chopper frame. I always wondered why it was shaped that particular way and the engineering rationale behind it. The components of this type of frame are the side members, the cross members, and the gusset plates figure 141. Feb 09, 2017 making a custom motorcycle frame jig using the tormach mill part 3 duration. How to design and construct a motorcycle engine powered race car. Whether youre looking to build a chopper, a prostreet, a softail, a rigid, an slx or a drop seat. Choose a paint system assuming you dont have an air compressor for this process, your paint selection is a little limited. Motorcycle frames started looking markedly different from bicycle frames in the earliest part of the 20th century. In 1977, harvey milk was elected to the san francisco board of. Whether you want to build a sport bike frame or a chopper frame, neither. The fatigue testing was done inhouse using a test rig specifically built for this project according to the astm standard f271108 for horizontal loading. Specialized software, such as motorcycle kinematics, matlab, catia, heeds professional, and nastran are utilized.
I think only book in the world for understanding motorcycle. All parts are fabricated in our enumclaw, washington shop from steel. Motorcycle handling and chassis design the art and science. 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.
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. The basics new riders and potential motorcycle shoppers need to know. Dmc sidecars now has available for the hobbyist, a doityourself, you weld it, sidecar frame kit. All this while, ive been pretty intrigued by the unique triangular pattern on the frame of my ktm duke 125. The side members, or rails, are the heaviest part of the frame. A motorcycle s chassis or frame forms its skeleton. 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. Motorcycle handling and chassis design the art and. Generally, lugless frames are found on inexpensive bicycles since it is the least. Motorcycle handling and chassis design the art and sciencetony foale warning important safety and legal notice. With a chop source frame jig kit you could have your motorcycle frame jig assembled in just a couple of hours.
Euro spares motorcycle chassis design and construction. 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. Motorcycle chassis design and construction and other technical topics. Pdf this paper presents a model of motorcycle frame made in the program adams view 2007 r1, as well as. Shoemark, pete 2002, motorcycle basics techbook 2nd ed.
We offer dozens of options allowing you to uniquely customize your bike. Basic motorcycle geometry trail rake or castor angle steering axis inclination wheelbase. This is the first in a series of tutorials on designing and sketching motorcycles. With a wide assortment of accessories including oil tanks, handlebars, fender struts and a springer, all bases are covered. Motorcycle suspension systems can be very complex, and involve numerous variables such as wheelbase, weight, ride height, tire size, suspension sag. 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. They have a little bit of rake, and they are slightly stretched compared to a sportster chopper frame. Make absolutely sure that every aspect of the project has been carefully considered in detail. All angle of lean and toe in must be done between the chair frame and the bike frame thus at the attachment points. A motorcycle frame is a motorcycle s core structure. What axle, hub and wheel to use and where to get it. These pages detail the design and build of a motorcycle sidecar. Ride basic comfort and handling need to be addressed through frame geometry rather than through special component choices at a later stage. 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 tutorial includes a 720p mp4 av file at 99 minutes in length, related jpegs of the 3 sketches done on camera. About 120 employees work in design, engineering and production, including 3 fulltime product designers and 3 engineers. Making a custom motorcycle frame jig using the tormach mill part 3 duration. 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.
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. Understanding a motorcycle parts diagram learn the basic parts of a motorcycle with a simple to read diagram. Designing and manufacturing of a handmade electric. 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. 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. They also come in a variety of materials and shapes. 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. Their design is done by bending the cold, and connect. Mounting a chair frame to the bike you will want all attachment points to be solid but adjustable. Anderson, engineer forest products laboratory forest service u.
A motorcycle frame is a motorcycles core structure. The thesis objective is to define and establish an engineering process for the design of a modern motorcycle chassis and suspension. We also build a wide assortment of accessories including gas tanks, oil tanks, handlebars, fenders and. How to build a motorcycle from salvaged and used parts. Carbonfibre is sometimes used in expensive or custom frames. 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. We addedd the background options to give your bike a cool stage, too. This is by no means an exhaustive guide on the building of chopper frames. Lets build a motorcycle building the frame jig youtube. In terms of importance, we order these three basic design parameters as follows. Strength and stiffness analysis of motorcycle frame ktu epubl. Conceptual design of a bicycle frame altair university.
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. Motorcycle handling and chassis design the art and science list of chapters. How to build motorcycleengined racing cars build your own. Motorcycle frame theory, design, function and improvement. 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. Please contact us with any questions on kit bikes or call 407 8470119. Material and design optimization for an aluminum bike frame. In addition to a 4person parts department, dirt bikes maintain a tenperson service department to service warranties and customer problems with parts and motorcycle performance. 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. There are two basic methods for building the main triangle of a frame. Motorcycle basics techbook by john haynes all common engine, chassis and electrical systems fully explained and illustrated. 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. The skill level required is alluded to throughout this article. The purpose of a motorcycles frame is to act as a base onto which all the various components can be bolted to.
In the beginning used on almost all vehicles, the ladder frame has. Home plans, floor plans, house designs design basics. Early motorcycle frames served chiefly as a mounting point for all the things that make a stack of tubing different from a motorcycle. These articles began when i asked if anyone on the lists was interested in the subject. 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 frame also serves as a support for the suspension system, a.
As different motorcycles have varying design parameters such as cost, complexity, weight. Old school chopper frame fabrication knucklebuster. If playback doesnt begin shortly, try restarting your device. Also attached to the frame are the fuel tank and battery. Here is a rigid sportster chopper frame 250 series. Conversely, here is the rigid bobber design, also by custom choppers guide. The swing arm assembly is prewelded for you and comes with the pivot bearings and seals. You can have fun draggin bike parts around the stage, changing the parts you want. Diy sidecar frame kit motorcycle sidecars, motorcycle. Understanding motorcycle rake and trail and suspension. A solid model of the frame was created and a finite element analysis fea was conducted using the astm standard as a. 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 frame consists mostly of hollow tubes and serves as a skeleton on which components like the gearbox and engine are mounted.
As you can see, these bobber style frame designs have more of a chopper look. The engineering process focuses on the interdisciplinary fields of engineering dealing with design and structural optimization. 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. Use your imagination and make a rough sketch and mention the specifications on the drawing. The strength of frame construction is correct design of a frame because it is the most important part that ensures safe riding. Heres 9 minutes of my 99 minute tutorial on the fundamentals of motorcycle design and sketching found on my gumroad account. So after some research on motorcycle frame and chassis design, i learnt that there are actually only 4 frame. 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. What do we need in our shops to attempt building a frame. We provide free help with kit purchase, paid consulting if you want to get your own parts elsewhere. 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.
Diy sidecar frame kit motorcycle sidecars, motorcycle trike. Euro spares motorcycle chassis design and construction and. 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. We also build a wide assortment of accessories including gas tanks, oil tanks, handlebars, fenders and springers to cover all the bases.
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. You have a bunch of parts and more will be ready in the future. Front and rear swing arm design of an electric racing motorcycle. Motorcycle chassis design and modification by jeffrey diamond. There is a lot tuning to be done to get the rig set up correctly. The fixtures are for sale individually or can be purchased in a kit to save money and fabrication time. Strength and stiffness analysis of motorcycle frame. Elementary aspects of road bicycle design, engineering and. This is just a small sampling of custom and oneoff frames and projects weve built for our customers. Build a complete chopper frame, hardtail a frame, rake your bagger, etc. 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. In this section we are going to construct a bicycle frame as shown below in.
Frame finishes design layout 17 case study measurement main frame engine mounting results material swing arm. 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. A look at how to approach a frame build and why youd want to tackle a build in the first place. May 12, 2014 understanding a motorcycle parts diagram learn the basic parts of a motorcycle with a simple to read diagram. 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. Motorcycles have a frame made of steel, aluminum or an alloy. Now that you know what are the things you need, lets move on to the procedure of making a motorcycle frame. 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. Very nice book to understand the dynamics of a motorcycle. 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. It supports the engine, provides a location for the steering and rear suspension, and supports the rider and any passenger or luggage. 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. 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. The frame also keeps the wheels in line to maintain the handling of the motorcycle.
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