How To Make A Mini Chopper

Learn how to make a mini chopper and save loads of cash. Motor bikes called Choppers look a lot like miniature versions of the Harley-Davidson choppers. Mini Choppers are also commercially available, but you can make your own. The Mini Chopper enthusiasts divide the hobby into two categories: Novelty and Serious. The Novelty versions costs anywhere from $350 to  $600. The Serious category of Mini Chopper cost quite a bit more and range from $2,000 and up depending on many options.

Things You Will Need to Make a Mini Chopper:

• 1 inch and 3/4^th an inch tubular steel
• One 1x1 inch steel angle
• One 1x1/4^th an inch steel strip
• One 6 and 1/2 horse power shaft of a 4 cycle engine (horizontal)
• One 2x1/4^th an inch steel strip
• Sprockets providing approximately 8:1 to 10:1 proportions spanning 2 stages No. 40 and No. 35 drive chain
• Clutch with centrifugal sprocket
• 2 wheels along with tires
• Saddle 
• Handle bars
• Disc brakes  
• Band saw (Portable)
• Arc welding equipment
• Tool box
• Grinder
• Drill
• Vise

1. Explore full size choppers you see on the road. Come up with your own ideas to choose the colors and designs to make a mini chopper. Make drawings of various parts of the engine such as the mounting, the drive, the front fork or handle bar and brakes. Use a computer drawing program, such as CorelDraw X5, to help design it. Use the formatting option draw out the dimensions of every piece. This will give you an idea how great it is going to look and in what location and scale. Try out different colors. Finalize the drawing by marking every piece by specifying direction it will have as well as its location before the frame gets welded.
2. Separate out the steel tubing. Cut out the pieces you need. Hold them on a vise. Use the saw to cut them. Grind or File the rough corners so that they become smooth. Mark every piece using marker giving each a code for its location. Now draw every piece the way they are shaped. Mark them as left or right, upper or lower and inner/outer as the case may be to avoid any confusion later. Try to keep the steps simple and organized when you build a mini chopper.
3. Take the time to jig or clamp to join the different pieces before being welded. Measure the assembled parts and make sure you use the squares generously. Bring a few pieces and secure them to start with. Choose three assemblies and then proceed with the others to be welded. After welding is done remove if there are any chips or slag hanging from the welded assemblies. Keep checking the measurements and straightness of every piece as it is added. Your attempt should be to make the pieces symmetric so that the frames form the correct shape when building a mini chopper.
4. Finish the mini chopper frame and check its rigidity. Attach the drive components, ensuring that all the components are connected by a huge steel frame. Identify the adjustment spots that point into the drive using turnbuckles, longer bolts, nuts, washers and rods (threaded). Connect disc brake on the wheels ensuring that they are lubricated. Assemble the wheels and attach the throttle cable. You are almost finish with the build of your mini chopper. Kick start the bike and ride it to test it. Adjust the mechanical components viz. tension in the chain, alignments, throttle and brake.
5. Disassemble the bike fasteners and the marked pieces. Degrease and clean the frame and all the components which will be finished and painted. After painting it, wait till it dries completely. Test ride and your mini chopper is ready.