Choppers Australia

Last two jobs on tank... Tank has a nasty deep fold on the right hand side from being hit by the forks in the accident that got this bike written off. Dent is forced out using a bar inside and heat... http://www.choppersaustralia.com/PictureLibrary7/CAFDiggensTankDent01.jpg Fortunately, this tank ha...

Mounting the fuel tank... We are using the stock tank because Garry will be travelling longish distances (He lives 200 miles from civilisation!) and because it is actually quite a good proportioned tank. We are making some changes though; front will be raised about 3", cowl that covers filler and f...

Rear Indicators... Haven't seen this done before, though I'm sure it has been. Makes for a very tidy set up and also a clean finish to the frame rails. Instead of the standard mounting procedure, we are pulling the electrics out of the indicators and mounting them in the end of each seat rail. Beca...

Taillight now; Garry peruses my display of tailights (the biggest range in SA) and picks out a few possibilities. Because the chopper has to go through the engineering and regio process, lights and reflectors have to be E Marked, even though there is no difference in quality... in fact the differenc...

Nice feeling when you can finally sit on the final version.

Four processes left on the seat; 1.fab up two sides, 2.built front mounts, 3. finish padding, 4. upholstery. The last will by Tony, a local motorcycle only upholsterer who has been in the business since Noah was a lad. Seat needs to be strengthened by building in side pieces under the passenger seat...

Mounting rear guard... I give Garry the usual selection of guards and he decides on a short flat guard with narrow valences. This CB750 rear guard gives the look he wants... http://www.choppersaustralia.com/PictureLibrary7/CAFDiggensRearGuard-00.jpg A new flat guard with a rear lip comes out of sto...

Sissy Bar... Garry and I played around with a few designs for a simple sissy bar. He liked a plain round top, but I suggested it be narrowed so the whole thing didn't look so wide. He was happy with this and we drew it up on a piece of particle board. I have made a number of formers over the years ...

Seat Mounting... Rear seat mount is also the rear guard support and ties the two rear frame tubes together, so needs to be reasonably substantial. Step one is to ensure it is square. This is done by measuring from a common point which in this case is a centre marked on the backbone ready to drill a...

That last picture shows the exciting part.

We need to build the seat first and then we can set up the guard and sissy bar mount... Measure at widest point. Seat width is same as centre (highest point) of each seat rail... http://www.choppersaustralia.com/PictureLibrary7/CAFDiggensSeat-00.jpg Guestimate the seat back height allowing for a sli...

Doing the final post on electrics box right now... Now for the sides. I will suggest that Garry have these chromed. So extra care is needed to keep them with out ripples that would show up once they are shiny. Once again the two sides are made from 2mm sheet steel. Here cut to basic size and rolled ...

Left side of battery box needs a floor. It will be supported by a welded in back. Swing arm is raised to its highest position so we can be sure the belt will clear. Always allow for the fact that the belt or chain describes a slight arc when it is under power. Here the back has been bent out of some...

Mounting electrics... With Garry 's approval I am building a traditional chopper style electrics box to house the battery and electrical components. Mounting the battery is a bit of a challenge due to its bulk. Unlike Harley, I will have the two terminals to the out side. Battery will also mount on...

Yes. That means that in SA you could get away with about 2.5" which is not very safe on a Motorcycle unless its a drag bike and doesn't go around corners!