old school chopper

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May 17, 2022
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This is a project I started over 3 years ago, and still have a long way to go.


I'm testing the electric at the moment. It's not working right yet.
Shimano Nexus 8 speed rear hub with coaster brake
Q100H front wheel hub with torque sensor bottom bracket.
26" 65mm alu rims from robinssons
Fat Frank tires 2.35"

The frame and fork is made from:
5/8", 7/8" and 1" round tube all with 1/16" wall.

I started with the rear frame, bending 5/8" tube in a loop around the tire.
I filled the tube with dry sand and caped the ends.
Using heat from a high end plumbers blow torch I slowly bended the tube around a jig.



Not perfect but acceptable.
Next the front end of rear frame, sand filled 5/8" tube cold bent around a 27" rim


The dropouts were cut from 5mm plate and the end of the of the pipe shaped to a bullet and tacked together

A piece of 7/8" tube was bent to be used as seat tube, it fits snuggly inside the 1" tube used as the top part of the frame.
2 lengths of 5/8" tube was bent and used for the underpart of the frame.


I purchased a seat spring to make the ride more comfortable and lift the seat free from the seat tube
The angle of the bottom bend was wrong and the bends not so good, so the bend was cut out and new bends made and spliced in.
All cables will be hidden inside the frame so entry and exit holes was made


A spiral wire was inserted as a future guide.
The front frame was tacked to the rear and brackets for the battery pack was welded in place
A real time update.
I'm working on a gear shifter.
I have purchased a reasonable priced chinese mini lath and this is the first time I'm using it.
From a tube I had, I adjusted the outside and inside in the lath.

glued on a piece of drawing as guidance for the cuts

cut a piece of tube to fit over the slots and some welding and grinding later

A round 10mm tube with a squashed 1/2" tube will be the T handle.

🤔 Doesn't look right to me, so back to the drawing board.

A better design I think.
So glue the drawing on to 3mm steel

and I can continue tomorrow.