Crazy Frank Fender build...

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Prof
Founder, Choppers Australia
Posts: 6018
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
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Crazy Frank Fender build...

Post by Prof » Tue Apr 28, 2015 11:13 pm

Back in the good ole days when classic choppers were young, some chopper jocks reckoned the rear suspension that was showing up on 10 year old second hand Harleys had its benefits, but there weren't too many options on this set up for a righteous looking king queen seat and sissy bar.

One cool (and apparently pretty wild) dude called Crazy Frank came up with a very neat, strong and definitely righteous solution... the Crazy Frank Fender...
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They are a great idea and gaining some recent popularity here but there aren't many of these beauties in Oz. A few enterprising individuals build them from scratch. Victor in SA is one and a number of others are keen to get there hands on one. One such guy is Jarrod who seeing Victor's build put up on these forums put in his request.

So why not build a few at The Chopper Shed. Victor was keen to leave his chopper with me to use his guard as a pattern and his shovel to set it up to Jarrod's requirements. Victor's chopper is lowered at the rear by a couple of inches while Jarrod's is stock. Victor runs a 16x5 whole Jarrod is fitting a 4.50x18. After a few emails and phone calls we set up Victor's rear wheel to match Jarrod's dimensions.

Here the wheel has been chocked up to mimic full compression and some spacing added for the extra diameter of the 18 incher. Top piece of guard (measured off Victor's guard) has been cut and rolled and laid on the spacers...
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Next the sides are cut out of 3mm plate...
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A couple of hours on the net produced a pile of photos of CFE fenders and I decided to use a slightly different mounting system to Victor's, but keep the rest of the fender close to his, because Jarrod reckoned it was just setup he wanted. Support bracket made from 5mm angle carries the weight of guard and passenger...
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First side blocked up and tacked. On the left top you can see the two 10mm pieces of threaded bar for the shocker bolt and rear support bolt...
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Second side done and both supports tacked on...
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Short rear curved section cut out and marked with parallel lines to make bending more accurate...
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Rolled in partly opened vice...
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Taillight and number plate panel measured up and curve marked out...
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Unlike the CFE fenders on the net, taillight is set forwards as Victor has done. First bend is done in bender. You can use a couple of pieces of angle in a vice to get the same result. Second bend is done in vice using a bluntened cold chisel. Takes some practice t get the hang of this method...
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Welded in and taillight mounted. Piece of metal being held is to contain a few tools, globes. fuses, tissues etc...!
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Side view...
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Now to make the seat base out of 3mm aluminium; stiff yet easy to bend and light. Designing a simple seat mounting system took some thought and discussion with Jake and we ended up with a super cool arrangement... two pins at the front of the guard and a couple of bolts at the rear. Here a couple of brackets have been welded in to take the pins...
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Aluminium is marked out, beginning with two parallel lines marking the widest part of the seat. A centre line is always essential if you want to get things right...
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First bend and overall length marked out...
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More measuring gives us the basic outlining including the slightly narrowing passenger section...
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Getting the front curve even. Draw in one side, trace it and poke some little marks in the ally with a sharp instrument...
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I generally cut the ally out with a jig saw my dad bought in about 1962. Still functioning a hundred percent after much hard work... Ally needs to be firmly clamped to bench top or it and jigsaw with bounce all over the place usually resulting in a bent or broken blade...
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An angle grinder with 1mm blade also works well if lubricated with wax. For curves use your left over small diameter blades...
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Main curve done in a sheet metal roller, but it could just as well be done using the method shown here where I am bending the small curve, wedging it between a piece of rectangular tube and a piece of water pipe...
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Hammering a depression in the nose to accommodate the shovel's backbone that sits higher that the seat rails...
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Fits nicely...
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With the seat base installed, I can make up a pattern for the taillight cover...
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Metal being cut out with small angle grinder disc. As I said don't throw them away...
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Cover is rolled at this angle (perpendicular to guard centre line...
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Welded in and seat base trimmed...
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Now we can do the locating pins at rear of rider's section of seat. They are made from 8mm round bar...
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... welded to a piece of 1" flat bar riveted to inside of seat base...
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Next job is the rim around the guard... made from 8mm round bar. We start by welding it in the centre so it can be folded around each side... or gee wiz... we could hang indicators on it. What do ya reckon Mr Plod?!!
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this job is a two person one. I heat and bend, Jake checks for alignment and tack welds as we go....
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The rim is faired into the support with a bit of flat bar suitably ground to shape. Jarrod will mould the rim for a smoothly curved finish...
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The rear seat bolts can now be set up. They don't need to screw into the seat, just hold it down. The angle of the front pins means that once the rear bolts pass through the seat base, the seat can't move. Here Jake welds the nuts on pieces of tube... (one on left is done)
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After a bit of careful measuring, the number plate panel is drilled and the tubes and nuts welded in place. You can see how the system works in the last photo...
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All that will show on the outside are the two bolt heads beneath the tail light...
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Sissy bar mounts are made of tube to take a 16mm (5/8th inch) round sissy bar. They are prebent at the bottom and then slash cut to provide a neat finish. The pins will be welded in each tube as a stop for the sissy bar...
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Lining the sissy bar mounts up was just about a three person job, but Stu was in the kitchen, so Jake and I just had to get it set up ourselves...
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Job pretty much done. I just have to do a bit of grinding on a couple of outside welds, drill a hole for the wiring and glue in a piece of plastic tube under the guard to protect the wires. This will be done first thing in the morning and then they'll be wrapped up and posted off. Hopefully Jarrod will be happy with the job. I'm sure Crazy Frank would approve of his legacy being continued into the next millennium.
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Chopit'nrideit... Prof

Bearcx
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Re: Crazy Frank Fender build...

Post by Bearcx » Wed Apr 29, 2015 10:15 am

Nice work, Prof. Looks good and solid. Like the idea of the removable sissybar.
The brave may not live long, but, the cautious do not live at all.

Prof
Founder, Choppers Australia
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Joined: Sat Oct 22, 2005 3:54 pm
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Re: Crazy Frank Fender build...

Post by Prof » Wed Apr 29, 2015 5:57 pm

Yes it is solid. Weighs 10 kilos. But it has to carry a lot of weight and it is cantilevered off two bolts only 3" apart. Needs to resist twist as well.

Here are a couple of final pics...

Today I glued in a piece of plastic tube to protect the taillight wires and drilled the appropriate holes. For holes in metal up to 2mm, I use a step drill. They double as a centre drill and create a very tidy, round easily drilled hole. Wire in the tube is mig wire and used to pull wiring through. Until fairly recently, I welded in copper tube for wires, but a few years ago discovered how strong Selley's Shoe Glue is... it just won't let go... so lighter and quicker to do.
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Side and end views...
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Wrapped up and on the bike to head off to Australia Post...
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Chopit'nrideit... Prof

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Wed Apr 29, 2015 8:24 pm

Looks absolutely stunning Prof, I love it mate! but the problem is I don't want to paint it now! I will post some pics once i mould & paint it..

Thanks for the hard work, Cheers..Jarrod

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Thu Apr 30, 2015 1:06 pm

Hey Prof

Fender arrived this morning so i ripped off the bratstyle fender & it bolted straight up without a problem (Even with the 19 x 3.25 rim & tyre) engineering excellence, Hat's off to you mate

Pics attached and i'll update some more as i go along with moulding and paint..Cheers, Jarrod

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Thu Apr 30, 2015 1:09 pm

After.....

Prof
Founder, Choppers Australia
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Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
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Re: Crazy Frank Fender build...

Post by Prof » Thu Apr 30, 2015 4:11 pm

Ah!!! Jenny shovel... my favourite looking HD engine. Thanks for the pics and looking forward to the finished painted job and upholstered seat. How do you like the seat locking setup?

Also, what do you think of the profile shape of the guard... any suggestions for an improved look?

I remember the double stacked triangular lights o a few bikes in the seventies. The deeper body to incorporate H4 globes looks pretty good tucked in as you have it. How good is the beam it throws?
Chopit'nrideit... Prof

Bearcx
Posts: 1894
Joined: Thu Oct 18, 2007 12:31 am
Location: Gawler, Sth Aust
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Re: Crazy Frank Fender build...

Post by Bearcx » Thu Apr 30, 2015 6:18 pm

Oooooooh.........nice.

Kicker, remote filter, dual calipers on the rear. Sweet !
The brave may not live long, but, the cautious do not live at all.

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Thu Apr 30, 2015 9:10 pm

Seat locking mechanism is simple and effective with the 2 allenhead bolts mate..i dropped it off to the trimmer this arvo

Guard profile is just what i was after, i like the way it slighlty cuts off the top line if the wheel (the rigid frame CFE fenders were a bit more rounded in relation to the wheel )

The only minor (MINOR) problem i had was to reroute the clear plastic tube for the light wiring around the lock nut on the inside of the top left hand side strut bolt..but that was it.

Aris triangle repop light does an ok job of illuminating the road (just) but it was between it and a square hella type..J

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Fri May 01, 2015 9:26 am

And didn't have to cut the fender around the horseshoe oil tank either..J

Prof
Founder, Choppers Australia
Posts: 6018
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
Contact:

Re: Crazy Frank Fender build...

Post by Prof » Fri May 01, 2015 10:00 pm

That's good. I didn't know how much space you had.

While I have Victor's bike I am making two more CFF's... one with standard suspension and one with two inches lowered, so if anyone wants one I have patterns to work off.
Chopit'nrideit... Prof

930tbo
Posts: 6
Joined: Sat Jan 03, 2015 2:47 pm
Location: Baulkham Hills, Sydney
Interests: Panshovel, Genshovel choppers.

Re: Crazy Frank Fender build...

Post by 930tbo » Sun May 03, 2015 10:46 pm

Pictures of the fender I moulded and painted with the first coat of flake, Plus a pic of the king & Queen seat @ the upholsterers..J

Prof
Founder, Choppers Australia
Posts: 6018
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
Contact:

Re: Crazy Frank Fender build...

Post by Prof » Mon May 04, 2015 8:01 am

Great to see some colour on a bike. Purple frame one day would really tie it all together. Looks like it will be done in time for the show.
Chopit'nrideit... Prof

Youngblood
Posts: 384
Joined: Wed Oct 24, 2007 1:48 pm
Location: North-Eastern suburbs- Adelaide

Re: Crazy Frank Fender build...

Post by Youngblood » Mon May 04, 2015 7:53 pm

I agree, it's good to see some colour
8) 8) 8)
Youngblood

El Skitzo
Posts: 827
Joined: Wed Sep 30, 2009 6:40 pm
Location: Perth, WA

Re: Crazy Frank Fender build...

Post by El Skitzo » Wed Apr 07, 2021 9:59 am

Hey Prof, do you remember roughly how wide this fender was?
'65 Triumph Chopper (project)
'64 Triumph Chopper (project)

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