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MINI CHOPPER PLANS BY
SOLUTION DESIGN (Revision2A Nov6, 05)
CLICK HERE TO REGISTER & UPDATE






































Frame#1 The Little Stretch (Page 6)
Frame#2 The Little Tyke (Page 27)
Frame#4 The Easy Brute (Page 62)
Frame#3 The Rat Fink (Page 41)
Frame#6 The Hulk (Page 90)
Frame#8 The High Boy (Page 116)
Frame#7 The Low Boy (Page 104)
Frame#5 The Black Widow (Page 74)
Most
Popular
Designed By Solution Design (Design Images not to be used without written permission)
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2
Need To Know How?
Need To Know NOW?
Then check out the worlds largest mini chopper resource
on the web!
HardCoreMiniChoppers.com
Heres a small sample of the topics you can learn from and
participate in:

Frame Building
Engines
Clutches/Torque Converters
Bodywork / Paint
Front ends
Electrical
Bar Stool Racers & Other Custom Rides

Some of the most knowledgeable builders in the industry
call the Hardcore Mini Chopper Forum home.shouldnt
you?

Welcome to Hardcore Mini Choppers
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INTRODUCTION

Research the necessary cost & tools required to start this project. It
would be a disappointment to start but never finish. Keep in mind that
you could rent or have the more complex work done for you if you do
not have the experience or the tools. Get written quotes for material
and labor. This will help protect you from being overcharged.
Tools Required
Tube bender
Welder, (I use a small Lincoln 135t portable welder)
Drill
Wrenches, sockets, grinder, screwdrivers, hole saw, etc.
Where to Begin
I started by building the frame, bending the necessary tubes to create the main
frame and the handlebars. I used the details I have provided to make these parts. I
tack-welded the frame only until I had the complete mini bike built. I wanted to
be sure the position of the handlebars; foot pegs and seat fit my nephew.
Make sure the engine and clutch are aligned straight with the rear sprocket. This
is critical to smooth operation.
Make sure the rear tire is also aligned straight. I used a make-shift wooden jig to
hold the frame while I measured to ensure the axel bolt was in the right position. I
drilled the holes first, then using clamps, positioned them in the right position
before tack welding.
Do not allow any pre-test runs before the brakes have been added. I have seen a
few minor spills that could have been much worse because the bike was ridden
without brakes.
Have all worked checked by a professional. Good welds are vital to safety!
Measure twice - cut once. Be safe!!!!! I miscalculated a few times and had to go
back for more tube. I found out that it is a heck of a lot more expensive when you
only buy in small quantities. Quite often the cut charge is more than the piece you
may have needed.


Use only D.O.M tube.
All water pipe, conduit, fencing, etc., have different properties. They
also are not a true and perfect diameter. When you bend these using a
precision bender, the bends are weak because they do not fit the dies
correctly.


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Disclaimer and Limitation of Liability


THE ENTIRE RISK AS TO THE QUALITY AND
PERFORMANCE OF MATERIALS, INFORMATION,
ACCURACY, ADEQUACY, COMPLETENESS,
CURRENTNESS, VALIDITY AND QUALITY OF
INFORMATION IS WITH THE USER. IN NO EVENT
WILL SOLUTION DESIGN BE LIABLE TO ANY
PARTY FOR ANY DIRECT, INDIRECT, SPECIAL,
PUNITIVE OR CONSEQUENTIAL DAMAGES OR
ANY CLAIM ATTRIBUTABLE TO ACCIDENTS,
MISHAPS, FIRES, ROLLOVERS, EXPLOSIONS,
FAILURES, ERRORS, OMISSIONS, OR OTHER
INACCURACIES IN, OR DESTRUCTIVE PROPERTIES
OF ANY MATERIALS, MANUALS, INFORMATION
ECT

READ THE FOLLOWING

ENGINES, AND THE EQUIPTMENT THEY DRIVE
ARE AND CAN BE VERY DANGEROUS TO
OPERATE. THEY ARE ALSO DANGEROUS TO
WORK ON. IT IS ASSUMED THAT ALL PERSONS
WORKING ON OR WITH THE MATERIALS IN
QUESTION ARE CERTIFIED AND QUALIFIED TO
WORK ON OR WITH THE REQUIRED TOOLS.


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Helpful Hints


Plan, Plan, Plan - Building on the fly is fun but can be costly! Take
the time to understand the project, the materials and the total cost.

Measure twice - cut once!!!!!!!!!!!!!!! This is the golden rule!!!!!!!!

Good professional welds are important!! Do not compromise
safety!!!!!

When welding the frame, tack it first!!!! You may want to change
the frame to fit your needs and a tack can be easily removed!

Build the jig; it is well worth the extra time. It will ensure the
frame is straight and accurate

Ebay has some great deals!!!!!!!!!!!! Shop around for the best
prices!

Be sure you have brakes! Resist the temptation of that first ride
unless the bike is complete.

Take your time!! Do not cut corners!! You will end up with a
much better final project

Be sure you know how to operate the required tools. If you dont,
seek the assistance of somebody who does. This project can be a
great learning tool.

Wear all necessary protective clothing when working with
grinders, welders, and other power tools.

Always wear safety glasses when working with ANY tools.






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Frame Bill Of Material

Item Name Description Purchased Fabrication
Reqd
Quantity
1. Frame D.O.M See frame B.O.M Yes Online links
2. Steering Neck D.O.M See frame B.O.M Could be either Online links
3. Engine mount plate See detail Could be either Online links
4. Axel hangers See detail Could be either Online links
5. Front gusset See detail Yes Online links
6. Jack shaft hangers See page Yes Online links
7. Fender supports See page Yes Online links
8. Fender mount brackets See page Yes Online links



Front End Bill Of Material
9. Front tire mount brackets See detail Could be either Online links
10. Front fork tubes See front end B.O.M Yes Online links
11. Triple Trees See detail Could be either Online links
12. Steering Bolt 3\4- 10nc x 6 long Yes Online links
13. Handle bar risers See detail Could be either Online links
14. Handle bars See detail Could be either Online links
15. Front tire assembly 16" or 20" See page Yes Online links
16.
17.
Engine Drive Train Bill of Material
18. 3.5hp - 6h.p side shaft engine I used a 5hp Tecumseh Yes Online links
19. Option #1 standard clutch & jack
shaft set-up
See page Yes Online links
20. Option #2 belt driven torque-
converter set-up
See page Yes Online links
21. Chain length to suit option 1 or 2 See page Yes Online links
Online links

Rear Wheel Bill Of Material
22. Axel hangers See page Yes Online links
23. Bearing cages See page Yes Online links
24. 1" Diameter bearings See page Yes Online links
25. 1" Diameter live axel with retainers See page Yes Online links
26. Rear tire size 18.8-8.5-8 for wide tire
frame
Or
15-6.00-6.00 for medium tire frame

See page

Yes


27. Rear Rim 4 bolt See page Yes Online links
28. Rear disc See page Yes Online links
29. Rear disc hub See page Yes Online links
30. Rim Hub See page Yes Online links
31. Rear sprocket See page Yes Online links
32. Rear sprocket hub See page Yes Online links
33. Throttle assembly See page Yes Online links
34. Front brake lever and cable See page Yes Online links



Custom Parts to Suit Your Taste
35. Gas tank See page Yes Online links
36. Seat See page Could be either Online links
37. Rear fender See page Yes Online links
38. Kick stand See page Yes Online links

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Mini Chopper #1 The Little Stretch
MEDIUM TIRE FRAME SERIES



REAR TIRE SIZE 15 X 6.00 6
FRONT TIRE 16 BICYCLE
ENGINE SIZE 2-6.5 HP



Suitable for riders who may want to convert their conventional mini bike into a mini bike
chopper .If you have never rode a stretched-out mini bike, you might be better off
moving on to the next frame - The Little Tyke




NOT SUITABLE FOR BEGINNERS

Riding mini bikes with stretched-out forks requires skill and balance. Learn the basics
on a conventional mini bike before graduating to a chopper

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8
Medium Tire Frame Bill Of Material










FRAME B.O.M

Detail # Material Wall Thickness Length Required
1 1.0Dia D.O.M .083 34.0
2 1.0Dia D.O.M .083 26 3/4
3 1.0Dia D.O.M .083 38.5
4 1.0Dia D.O.M .083 38.5
5 1.0Dia D.O.M .083 12 21/32
5a 1.0Dia D.O.M .083 12 21/32
6 1.0Dia D.O.M .083 20 7/16
7 1.0Dia D.O.M 083 18.5
8 (3 Required) 1.0Dia D.O.M .083 9.0
9 1.0Dia D.O.M .083 10 3/32
10 1.0Dia D.O.M Note***.120 6 1/4


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FRAME DETAIL #1

Tube length 34.0, Diameter 1.0, Wall thickness .083
Two notches required

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FRAME DETAIL #2

Tube length 26 3/4, Diameter 1.0, Wall thickness .083
Two 90 degree bends required
I like to add a few extra inches to the ends and trim them to length when I tack
weld the frame









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FRAME DETAIL #3

Tube length 38.5, Diameter 1.0, Wall thickness .083
One 75 degree bend with a 15 degree tube notch
Bend radii is 3.5


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FRAME DETAIL #4

Tube length 38.5, Diameter 1.0, Wall thickness .083
One 75 degree bend with a 15 degree tube notch
This notch is opposite to that of detail #3 (See 3D view for more info)
Bend radii is 3.5


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FRAME DETAIL #5



Tube length 12 21/32, Diameter 1.0, Wall thickness .083
One notch and minor grinding to match to center frame tube
(See 3D View for more info)









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FRAME DETAIL #5a


Tube length 12 21/32, Diameter 1.0, Wall thickness .083
One notch and minor grinding to match to center frame tube
(See 3D View for more info)










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15
FRAME DETAIL #6

Tube length 20 7/16, Diameter 1.0, Wall thickness .083
Two notches required

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16
FRAME DETAIL #7

Tube length 18.5, Diameter 1.0, Wall thickness .083




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17
FRAME DETAIL #8


Tube length 9.0, Diameter 1.0, Wall thickness .083
Two notches required
3 of these required for seat & jack shaft mounting






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FRAME DETAIL #9


Tube length 10 3\32, Diameter 1.0, Wall thickness .083
Two notches required






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19

FRAME DETAIL #10

Tube length 6 1/4, Diameter 1.0, Wall thickness .120



ENGINE MOUNT PLATE

Use plate steel 3\16 thick
Center your engine and then transfer holes




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AXEL & FRAME MOUNT PLATE

Use 1\4 thick plate steel if making these from scratch
The hanger below is a modified hanger that you can buy cheap, just weld a
triangle shape extension to the top of the hanger to match the frame angle
See the assembly views in the rear for axel and bearing mount info
Transfer bearing mount holes to ensure proper pattern
These can also be purchased on my website minichopperplans.com









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FRAME GUSSET

Use 3\16 thick plate steel

When your frame is complete and you are happy with the angles and the position
of the forks, be sure to add frame gussets. You can use a cardboard template and
make a mock gusset and then trace it onto your plate steel.












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MEDIUM TIRE FRAME JIG







This is the most important step in building
your frame, this jig will ensure the frame is
assembled straight and accurate




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Medium Tire Frame Jig Bill Of Material




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Frame Assembly Information

Clamp or screw axel hangers in position, then tack weld


Weld detail 1, 2 & 10 together to make a sub-assembly

Finish the frame by measuring to be sure the frame details are in
their proper position
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Main Starting Point for The Frame


1. Begin by tack welding the lower frame rails, foot rest and rear support. The
position of the rear support is dependant on the size of your rear tire. I also use it
to hold the rear fender. Only tack weld these pieces !!!!!!!!!!!!!!!!!!!!!!!!!!! You
may run into problems and find you would like to move some of the frame
parts !!!!!!!!!

This set up will be the most important!




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Medium Tire Frame Side Profile
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Mini Chopper #2 The Little Tyke

REAR TIRE SIZE 15 X 6.00 6
FRONT TIRE 16 BICYCLE
ENGINE 2-6.5HP

Suitable for young riders and smaller engine sizes (2hp to 6.5hp).
One of the benefits of a frame this size is the availability of parts. Most of these parts can
be purchased from a go-kart or mini-bike parts supplier. This is a great frame for younger
riders because the forks are not as stretched-out as other models.



A GREAT
BEGINNER
BIKE
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FRAME DETAIL #1

Tube length 34 1\4, Diameter 1.0, Wall thickness .083
One notch required



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FRAME DETAIL #2A & 2B

Tube length 14 3\4, Diameter 1.0, Wall thickness .083
One notch required per detail



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FRAME DETAIL #3 & 4

Tube length 53 1\4, Diameter 1.0, Wall thickness .083
One notch required per detail



FRAME DETAIL #5

Tube length 9.0, Diameter 1.0, Wall thickness .083
Two notches per detail



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FRAME DETAIL #6

Tube length 9 5\8, Diameter 1.0, Wall thickness .083
Notch 2 Places


FRAME DETAIL #7

Tube length 9 5\8, Diameter 1.0, Wall thickness .083





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ENGINE MOUNT PLATE DETAIL

Use 1\8 mild steel plate


FORK DETAILS

Use 1 1\2 .085 wall tube





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Little Tyke Rear Profile






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Little Tyke Frame Dimensions



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The Little Tyke Jig Bill Of Material







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Frame Assembly Information


Fasten details 3 & 4 into the wooden jig
Screw or clamp the axel hangers into position
Weld the steering neck, detail #1, detail #2A, detail #2B and detail #7, together
then place into the jig
Check to make sure all components are straight then tack weld
Once complete, remove the frame, weld completely, and then move onto the drive
train

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Mini Chopper #3 The Rat Fink
WIDE TIRE FRAME SERIES


REAR TIRE SIZE 18.5 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9HP



NOT SUITABLE FOR BEGINNERS

Riding mini bikes with stretched-out forks requires skill and balance. Learn the basics
on a conventional mini bike before graduating to a chopper










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Wide Tire Tube Frame Bill Of Material






FRAME B.O.M

Detail # Material Wall Thickness Length Required
1W 1.0Dia D.O.M .083 38 11/32
2W 1.0Dia D.O.M .083 30 11/16
3W 1.0Dia D.O.M .083 43.5
4W 1.0Dia D.O.M .083 43.5
5W 1.0Dia D.O.M .083 17 5/32
5aW 1.0Dia D.O.M .083 17 5/32
6W 1.0Dia D.O.M .083 20 7/16
7W 1.0Dia D.O.M Note*** .120 23.0
8W (3 Required) 1.0Dia D.O.M .083 12.5
9W 1.0Dia D.O.M .083 11 1/8
10W 1.0Dia D.O.M Note***.120 6 1/4





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FRAME DETAIL #1

Tube length 38 11/32, Diameter 1.0, Wall thickness .083
Two notches required


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45

FRAME DETAIL #2

Tube length 30 11/16 , Diameter 1.0, Wall thickness .083
Two 90 Degree bends required. I like to add a few extra inches to the ends and
trim them to length when I tack weld the frame













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FRAME DETAIL #3

Tube length 43.5, Diameter 1.0, Wall thickness .083
One 75 Degree bend with a 15 degree tube notch, Bend radii is 3.5



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FRAME DETAIL #4

Tube length 43.5, Diameter 1.0, Wall thickness .083
One 75 Degree bend with a 15 degree tube notch, Bend radii is 3.5
Be sure to notch the tube opposite of detail #3



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FRAME DETAIL #5



Tube length 17 5/32, Diameter 1.0, Wall thickness .083
One notch and minor grinding to match to center frame tube
(See 3D View for more info)

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FRAME DETAIL #5a


Tube length 17 5/32, Diameter 1.0, Wall thickness .083
One notch and minor grinding to match to center frame tube
(See 3D View for more info)

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FRAME DETAIL #6

Tube length 20 7/16, Diameter 1.0, Wall thickness .083
Two notches required

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FRAME DETAIL #7

Tube length 23.0, Diameter 1.0, Wall thickness .083



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FRAME DETAIL #8


Tube length 12.5, Diameter 1.0, Wall thickness .083
Two notches required





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FRAME DETAIL #9


Tube length 11 1/8, Diameter 1.0, Wall thickness .083
Two notches required





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54

FRAME DETAIL #10

Tube length 6 1/4, Diameter 1, Wall thickness .120




ENGINE MOUNT PLATE

Use 3\16 thick plate steel
Center your engine and then transfer holes


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55
AXEL & FRAME MOUNT PLATE


Use 1\4 thick plate steel if making these from scratch
The hanger below is a modified hanger that you can buy cheap. Just weld a
triangle shape extension to the top of the hanger to match the frame angle
See the assembly views in the rear for axel and bearing mount info
Transfer bearing mount holes to ensure proper pattern
These can also be purchased on my website minichopperplans.com








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FRAME GUSSET

Use plate steel 3\16 thick

When your frame is complete and you are happy with the angles and the position of the
forks, be sure to add frame gussets. You can use a cardboard template and make a mock
gusset and then trace it onto your plate steel.












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JIG WIDE TIRE FRAME





This is the most important step in building your
frame; this jig will ensure the frame is assembled
straight and accurate



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Wide Tire Frame Jig Bill Of Material

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60
Frame Assembly Information

Clamp or screw axel hangers in position, then tack weld


Weld detail 1, 2 & 10 together to make a sub-assembly

Finish the frame by measuring to be sure the frame details are in their
proper position
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61

Main Starting Point for The Frame


Begin by tack welding the lower frame rails, foot rest and rear support. The position of
the rear support is dependant on the size of your rear tire. I also use it to hold the rear
fender. Only tack weld these pieces !!!!!!!!!!!!!!!!!!!!!!!!!!! You may run into
problems and find you would like to move some of the frame parts !!!!!!!!!

This set up will be the most important!


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WIDE TIRE FRAME DIMENSIONS



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Mini Chopper #4 The Easy Brute

WIDE TIRE FRAME SERIES


REAR TIRE SIZE 18 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9 HP
NOT SUITABLE FOR BEGINNERS

Riding mini bikes with stretched out forks requires skill and balance. Learn the basics
on a conventional mini bike before graduating to a chopper









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65

FRAME DETAIL #1

Tube length 37 5/8, Diameter 1.0, Wall thickness .083
Two notches required

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66

FRAME DETAIL #2

Tube length 30 3/4, Diameter 1.0, Wall thickness .083
Two notches required

FRAME DETAIL #3


Tube length 12 1\2, Diameter 1.0 Wall thickness .083

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67
FRAME DETAIL #4
Tube length 53 1\4, Diameter 1.0, Wall thickness .083
One notch required

FRAME DETAIL #5

Tube length 53 1\4, Diameter 1.0, Wall thickness .083
One notch required

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FRAME DETAIL #6

Tube length 11 1/8, Diameter 1.0, Wall thickness .083
Two notches required


Engine Plate Detail

Use 3\16 thick mild steel plate

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Frame Profile




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The Brute Jig





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Screw together - Do not nail


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74

Load details 3, 4, & 5 into the jig
Weld detail #1 to the steering neck outside of the jig
Screw or clamp the axel hangers into position
Tack weld detail #2 to the axel hangers
Tack weld in detail #1 with the steering neck
Check to make sure all components are straight, then tack weld
Once complete, remove the frame, weld completely and then move onto the drive
train

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75

Mini Chopper #5

The Black Widow


WIDE TIRE FRAME SERIES

REAR TIRE SIZE 18.5 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9 HP

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77
Detail #1
For this detail use a 1 Diameter, .083 Wall, D.O.M Tube 37 11/16 long
Make two notches as shown below
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Detail #2
For this detail use a 1 Diameter, .083 Wall D.O.M Tube, 34 1/8 long
Make (2) 90 degree bends and (2) 50 degree bends as shown below

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Detail #3

For this detail use a 1 Diameter, .083 Wall D.O.M Tube 36 1\8 long
Make (2) 90 degree bends and (2) 17 degree bends as shown below

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Detail #4 & #6

For this detail use a 1 Diameter .083 Wall D.O.M Tube, 10 3/8 long
Make one bend & two notches
This detail does not have to be exact. It will hold the jack shaft mounting tabs







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Detail #5
For this detail use a 1 Diameter .083 Wall D.O.M Tube, 12 1\2 long
Make two notches

Engine Mount Plate Detail
For the engine mount plate, use a 12 X 7 3\4 plate, 3\16 thick
Transfer the holes from the engine to mount in the proper location




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82
Detail #7 & Detail #8

For this detail use a 1 Diameter .083 Wall D.O.M Tube, 50 1\8 long
Make one bend and add two notches to complete
A compound notch will be required to fit this tube to the neck
Make sure the notch at the steering neck matches the neck tube diameter









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BLACK WIDOW JIG






This is the most important step in building your
frame; this jig will ensure the frame is assembled
straight and accurate







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Black Widow Jig Bill Of Material



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87
Frame Assembly Information















Clamp or screw axel hangers in position, then tack weld
Weld detail 1 & 9 together but measure to make sure it is centered





Use clamps to align the frame and make sure all the frame pieces are square
Only tack weld the frame first! You may want to make a change later
Measure and Measure! Make sure the frame pieces are in the proper location!
Detail #4 & #6 will mount as shown, these will hold the jack shaft


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88

Black Widow Frame Side Profile





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89

Black Widow Rear Profile




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91
Mini Chopper #6 The Hulk
WIDE TIRE FRAME SERIES

REAR TIRE SIZE 18.5 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9 HP






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Detail #1
For this detail use a 1 Diameter .083 Wall piece of D.O.M tube, 36 1\8 long
Notch both ends as shown
The 25 degree notch must match the steering neck tube diameter




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94

Detail #2 & #3


For this detail use a 1 Diameter .083 Wall D.O.M Tube 36 1\8 long
Detail #2 and #3 are the same








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95
Detail #4 & #5
For this detail use a 1 Diameter, .083 Wall D.O.M Tube 49 1\8 long
Make one bend and add two notches to complete
A compound notch will be required to fit this tube to the neck
Make sure the notch at the steering neck matches the neck tube diameter







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Detail #6 & #7

For this detail use a 1 Diameter, .083 Wall D.O.M Tube 10 3/8 long
Make one bend & two notches
This detail does not have to be exact. It will hold the jack shaft mounting tabs







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97
Detail #8
For this detail use a 1 Diameter, .083 Wall D.O.M Tube 11 1/16 long
Make two notches to match frame

Engine Mount Plate Detail
For the engine mount plate use a 12 X 7 3\4 plate 3\16 thick
Transfer the holes from the engine to mount in the proper location





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The HULK JIG





This is the most important step in building your
frame; this jig will ensure the frame is assembled
straight and accurate



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The Hulk Bill of Material



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102
Frame Assembly Information



















Clamp or screw axel hangers in position, then tack weld
Weld detail 1 & 9 together but measure to make sure it is centered

















Use clamps to align the frame and make sure all the frame pieces are square
Only tack weld the frame first! You may want to make small changes later
Measure carefully! Make sure the frame pieces are in the proper location!
Detail #6 & #7 will mount as shown; these will hold the jack shaft

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The Hulk Frame Side Profile







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The Hulk Rear Profile



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105
Mini Chopper #7 The Low Boy
WIDE TIRE FRAME SERIES

REAR TIRE SIZE 18.5 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9 HP




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FRAME DETAIL #1

Tube length 33 1/4, Diameter 1.0, Wall thickness .083
Two notches required



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The Low Boy Side Profile




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109


The Low Boy Jig

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BE SURE TO SCREW THE JIG TOGETHER
DO NOT NAIL
PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT
CRACK THE WOOD
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FRAME DETAIL #2 & #3

Tube length 36.0, Diameter 1.0, Wall thickness .083
Two bends required












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Detail #4
For this detail use a 1 Diameter, .083 Wall D.O.M Tube, 11 1/16 long
Make two notches to match frame

Detail #5 & #6
For this detail use a 1 Diameter, .083 Wall D.O.M Tube, 10 3/8 long
Make one bend & two notches
This detail does not have to be exact. It will hold the jack shaft mounting tabs

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Detail #7 & Detail #8
For this detail use a 1 Diameter, .083 Wall D.O.M Tube, 44 1\8 long
Make one bend and add two notches to complete
A compound notch will be required to fit this tube to the neck
Make sure the notch at the steering neck matches the neck tube diameter

Engine Mount Plate Detail
For the engine mount plate use a 12 X 7 3\4 plate, 3\16 thick
Transfer the holes from the engine to mount in the proper location



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The Low Boy Side Profile

Load details 7, 8, & 3 into the jig
Weld detail #1 to the steering neck outside of the jig
Screw or clamp the axel hangers into position
Tack weld detail #2 to the axel hangers
Tack weld in detail #1 with the steering neck
Check to make sure all components are straight, then tack weld
Once complete remove the frame, weld completely, and then move onto the drive
train
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Mini Chopper #8 The High Boy
WIDE TIRE FRAME SERIES

REAR TIRE SIZE 18.5 X 8.5 8 OR 205-50-10
FRONT TIRE 20 BICYCLE
ENGINE SIZE 2-9HP





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FRAME DETAIL #1

Tube length 36 1/8, Diameter 1.0, Wall thickness .083
Two notches required

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FRAME DETAIL #2 & #3
Tube length 36.0, Diameter 1.0, Wall thickness .083
Two bends required

FRAME DETAIL #4 & #5
Tube length 31 7/8, Diameter 1.0, Wall thickness .083
One bend & two notches required



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FRAME DETAIL #6
Tube length 21 3/8, Diameter 1.0, Wall thickness .083
One notch required


Engine Mount Plate Detail
For the engine mount plate use a 12 X 7 3\4 plate 3\16 thick
Transfer the holes from the engine to mount in the proper location


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FRAME DETAIL #7


Tube length 11 1/16, Diameter 1.0, Wall thickness .083
Two notches required












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Detail #8 & #9

For this detail use a 1 Diameter, .083 Wall D.O.M Tube, 10 3/8 long
Make one bend & two notches
This detail does not have to be exact. It will hold the jack shaft mounting tabs






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The High Boy Side Profile




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The High Boy Jig Plans



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BE SURE TO SCREW THE JIG TOGETHER
DO NOT NAIL
PRE DRILL THE SCREW HOLES SO THAT YOU DO NOT
CRACK THE WOOD



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Load details 3, 4, & 5 into the jig
Weld detail #1 to the steering neck outside of the jig
Screw or clamp the axel hangers into position
Tack weld detail #2 to the axel hangers
Tack weld in detail #1 with the steering neck
Check to make sure all components are straight, then tack weld
Once complete, remove the frame, weld completely, and then move onto the drive
train
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MINI CHOPPER FRONT END PLANS FOR BOTH
MEDIUM AND WIDE TIRE
FRAMES


Detail # Material Wall Thickness Length Required
1 D.O.M .083 20.0
2 D.O.M Note*** .120 7.0
3A D.O.M Note*** .120 6.25
3B D.O.M Note*** .120 6.25
4 PLATE STEEL SEE DETAIL N\A
5 D.O.M Note*** .120 40.0
6 BAR STOCK SEE DETAIL AS REQD
7 PLATE STEEL SEE DETAIL SEE DETAIL
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DETAIL #1

Tube length 20 , Diameter 7/8, Wall thickness .083
Two bends required, bend radii is 3.5

BE SURE TO USE 7\8 DIAMETER TUBE FOR YOUR HANDLE BARS, THIS IS
THE INDUSTRY STANDARD. MOST HAND LEVERS AND CONTROLS ARE
DESIGNED TO FIT 7\8 HANDLE BARS. IF YOU USE 1 YOU WILL HAVE A
TOUGHER TIME FINDING LEVERS



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Detail#2
Tube length approximately 8.0 , Diameter 1.0, Wall thickness .120
Notch for 7\8 handle bars
Make the riser to suit your body position. You may also wish to buy a bolt-on type riser. I
formed mine by cutting the arc on a 2x6. I heated the tube and bent it to the desired arc. I
then welded it to the triple trees.

FRAME DETAIL #3A & 3B STEERING NECKS
The most common steering neck is a 1 5\8, .120wall piece of D.O.M tube (this
will require two bearings to be pressed-in). This is the best way to go!
Some older frames use a 1, .120 wall tube. This requires no bearings.



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FRAME DETAIL #4

** Scale this on a photocopier to use as a tracing template, use the
dimensions to check scale accuracy.




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FRAME DETAIL #5 & #6

Tube length 40, Diameter 1.0, Wall thickness .120















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FRAME DETAIL #6


1\4 PLATE 1.5 X 3.75
Weld this detail to the forks, it can be welded on center or to the inside as shown
below






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Mounting the Forks to the Frame!
Option #1

Mount the forks to the frame using a 3\4-10nc x 8 or 1\2-16nc x 8 bolt

Option #2

You may also choose to replace detail 3 with a 1 5\8, .120 wall D.O.M tube; this
will allow you to use bearings in the neck. You will have to adjust the tube
notches on the other frame components.

Option #1



Option #2














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Jack Shaft Drive







1 Clutch More Info
2 Locking collar More Info
3 Bearing More Info
4 Jack shaft More Info
5 Sprocket More Info
6 Locking collar, bearing, Flangettes More Info
7 1 Diameter axel shaft & locking key More Info
8 Wheel hub More Info
9 Sprocket hub More Info
10 Rear sprocket More Info
11 Chain to match your sprockets More Info

The above picture shows a jack shaft set-up, which has been used to
redirect power to the opposite side of the bike. To mount a jackshaft
you must weld two jackshaft mounting tabs to the frame. See the
following page.
6
7
8
9
10
4
1
2
3
5
11
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Jack Shaft Mounting Info

Medium Tire Frame












Wide Tire Frame


For the chain to clear the frame you will need to mount the
jackshaft mount tabs above the base of the frame
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Torque Converter Drive

A torque converter set up is not as complicated as it may sound. When
you buy the unit it comes complete with everything you will need to mount
it and use it. In most cases you can install one of these units in about 15
minutes. The unit will bolt to your engine using 4 bolts. The primary drive
pulley will mount to your engines shaft.

T



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If you choose to use a torque converter set-up you will need to add a
roller. I used a roller from a two-stroke dirt bike and mounted a small
bracket to the frame. This will act as a support and guide to the chain
and keep it from rubbing on the frame.


Comet Torq-A-Verter TAV2-30
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Live Axels Continued


Above you have a complete live axel set up




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Rear Brakes
Below I show a mechanical type brake caliper. This unit will need to be
mounted to the frame. There are other options such as hydraulic disc brake
set-ups and friction bands.
If you are planning to use a mechanical brake system, I suggest the rotary
brand mechanical disc brake part# 04-9306.

The rotary brand mechanical brake as shown above is one of the best
mechanical brakes available.

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Hydraulic Disc Brakes

You can dress up your chopper with a tricked-out hydraulic brake system. The
rear disc brake can be easily mounted using two bolts as shown below. The pedal
assembly will mount the same way.




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Other Rear Brake Options

Clutch Band
Clutch Band: This style of brake is common on mini bikes.
Using an angle iron bracket, it rides on the clutch. As the brake
is activated, the band tightens around the clutch, stopping the
bike.



Rear Drum Brake

Rear Drum: There is also a drum style brake available. I have
never used one, but they do look slick.





Caliper Type Disc Brake

The caliper brake system shown below rides on the rear drive
sprocket. This unit can be mounted by making a custom
bracket.






Chain Guard

Dont forget safety! Be sure to protect
your little riders by adding a chain guard.
This unit is available at mfgsupply.com



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Custom Front Pegs

Here are a few screen shots of my tricked-out foot pegs. I wanted a look that was a little
different and was quite pleased with the results.















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You can even make the seat

Make a seat frame with 2 pieces of plywood cut to fit your frame.
Glue high density foam to the plywood
Then cover with leather, vinyl or any material you choose
Staple the covering to the wood
Hot-glue a piece of felt to hide the wood and staples














Choose your look!!!!



















If old school is the look you are after, try adding a solo seat and a set
of ape hanger handlebars

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Helpful Info












If your seat rides on the fender. Be sure to add supports!!!!!!!!!!!!!!!!!!!!!!!!!!!!

This is when you will want to be sure your engine fits correctly.
Also be sure your rear tire has enough clearance.
If you are using a rear disc brake, be sure the width of the frame is adequate.
Also check for proper alignment from the rear sprocket to the front drive sprocket.
I use a long straight edge to be sure they are straight.
This is a good time to position the engine mount plate and holes.


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Tube Notch Templates
Cut the following templates and tape or scribe the profile onto your tube.
You can then grind the contour for an accurate tube notch





SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.
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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.




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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.




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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.






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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.






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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.



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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.



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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.





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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.




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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.





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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.




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SOME PRINTERS MAY DISTORT THE SCALE OF THESE
TEMPLATES. IF YOU MEASURE THE DIMENSIONS AND
FIND THEY ARE NOT TO SCALE, USE A PHOTOCOPIER TO
RETURN THEM TO THE PROPER SIZE. THIS CAN BE
EASILY DONE BY EXPANDING OR SHRINKING THE
DRAWING USING THE PHOTOCOPIER CONTROLS.






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P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
More info at www.minichopperplans.com
COPYWRIGHT 2002, SOLUTION DESIGN
NOT TO BE RESOLD OR CIRCULATED
159
High Quality Parts

TRIPLE TREES
AXEL HANGERS
&
FRONT TIRE MOUNT BRACKETS

AVAILABLE AT

https://www.minichopperplans.com/


Designed By Solution Design (Design Images not to be used without written permission)
P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
More info at www.minichopperplans.com
COPYWRIGHT 2002, SOLUTION DESIGN
NOT TO BE RESOLD OR CIRCULATED
160

Online Part
Suppliers



U.S Parts Suppliers

www.bmikarts.com
www.mfgsupply.com
www.tricountysupply.com
www.gokartsupply.com
www.cvmkarts.com
http://www.georgessales.com/
www.johnsgokarts.com
www.jsesc.com
www.crosstec.com
www.minibikekits.com

Canadian Parts Suppliers

www.gokartexpress.com
www.idealkarts.com




Thanks & Good Luck!

Designed By Solution Design (Design Images not to be used without written permission)
P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
More info at www.minichopperplans.com
COPYWRIGHT 2002, SOLUTION DESIGN
NOT TO BE RESOLD OR CIRCULATED
161


Other Projects Available From
Solution Design

1.5 Diameter tube bender plans

1.0 Diameter tube bender plans

6 X 10 Utility trailer plans

2 Seat Dune Buggy Plans

4 Seat Dune Buggy Plans

Mini Bike Plans

Designed By Solution Design (Design Images not to be used without written permission)
P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
More info at www.minichopperplans.com
COPYWRIGHT 2002, SOLUTION DESIGN
NOT TO BE RESOLD OR CIRCULATED
162
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call the Hardcore Mini Chopper Forum home.shouldnt
you?

Welcome to Hardcore Mini Choppers

Designed By Solution Design (Design Images not to be used without written permission)
P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
More info at www.minichopperplans.com
COPYWRIGHT 2002, SOLUTION DESIGN
NOT TO BE RESOLD OR CIRCULATED
163