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Author Topic: CR200 Chopper Project by cyclhed  (Read 9676 times)

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #20 on: Jan 20, 2013, 14:59:02 »
I scored a 21" narrow hub front wheel, but the hub is still too wide for the brake rotor to fit.

I'm trying to get my head around how to bend the lower rails and it's giving me headaches! I'm using a single 1.5" down tube and I want it intersect the head tube near the bottom of the head tube. Complicated....I bent up some pieces of wire to try to visualize it. There are 5 bends and 3 rotations in each tube...I think.
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline DesmoBro

  • Posts: 2398
  • Busted Nut
Re: CR200 Chopper Project by cyclhed
« Reply #21 on: Jan 20, 2013, 17:08:11 »
Good luck with those lower rails...So Far So Good this clearly isn't your first picnic, Have fun with it
"I desire the things that will destroy me in the end"

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #22 on: Jan 20, 2013, 20:52:14 »
Thanks DesmoBro. A friend suggested I bend up some electrical conduit to check it out first which is a great idea. I'm going to go try that now. I'll let you know how it goes.
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #23 on: Jan 29, 2013, 12:28:43 »
OK time for a little update...

I got the pattern done in 1" EMT for the lower rails and I will try to get them bent up this week. Here are some pics of the set-up.
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #24 on: Feb 04, 2013, 05:10:08 »
OK this weekend I got the right lower rail done up to the point at the front of the motor. I need to figure out the bend angle and amount of rotation for this one, so I stopped here and I will practice with some more 1"EMT conduit before I finish bending it.

An easy way to work with this 1.25" OD tubing (if anyone cares) is to divide it into sections and then converting the degrees into length around the tube. Doing it this way you can use a flexible tape measure to mark degrees of rotation on the tube in inches.
The approximate circumference is 4 inches, so 90 degrees is 1", and 10 degrees is 1/8". The numbers are rounded to the nearest fraction, but it works out very well with no error.

Also you need a good way to mark the tubing all the way around. I made a tool to do this from an old BMX bike foot peg that fits snug around the tube. To mark the tube length way use a piece of 1" angle and lay the tube in it and mark with a sharpie.
« Last Edit: Feb 04, 2013, 05:17:55 by cyclhed »
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #25 on: Feb 04, 2013, 05:16:07 »
Oh and I screwed up and made the rear kick up too short so I'll add a 2 inch piece to the end to fix that. It's starting to look like like a motorcycle now (sort of).
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #26 on: Feb 10, 2013, 01:16:31 »
I cut out the axle plates and machined the slot with the help of my bro and his Bridgeport. We also cut out the rear motor and front trans mounts and the forward mounts. I also bent up the left side lower tube and it matches the right side nicely. I wanted to put the large 66" radius bend in the front down tube, but the 3' foot length of tube I have was too short to use in my brothers large tube roller. I'll need to pick up a longer piece in order to roll the radius.   
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #27 on: Feb 17, 2013, 11:21:38 »
I figured out the final bend for the lower tubes. I rotated the tube 0.750" and made a 46* bend in to the center to bring the tubes together at the down tube. I just need to finish cutting the miters. It turned out looking pretty good I think. I'm not sure how I'll finish the bottom of the down tube, maybe just cap it or leave it open.
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline cyclhed

  • Posts: 370
    • Irish Cycles
Re: CR200 Chopper Project by cyclhed
« Reply #28 on: Feb 19, 2013, 00:41:01 »
It's starting to look like a frame. Almost time to start tacking it together. It's a lot of grinding and filing to get it to fit together. It's a fun challenge. If it's straight to within an 1/8" or so you're good after welding it. 
540cc CB360 Honda engine cafe' Project: http://www.dotheton.com/forum/index.php?topic=39496

CR200 Chopper Project: http://www.dotheton.com/forum/index.php?topic=28969

CL100/SL125 Cafe' Project: http://www.dotheton.com/forum/index.php?topic=36548

SL-350 Super Moto-Sport Project: http://www.dotheton.com/forum/index.php?topic=27751

Twowheelin' since '62!

Offline Joon-yah

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Re: CR200 Chopper Project by cyclhed
« Reply #29 on: Feb 19, 2013, 11:43:45 »
lookin good man
Cm400/cb450 http://www.dotheton.com/forum/index.php?topic=45376.0                                                  SR500 http://www.dotheton.com/forum/index.php?topic=43591.0                                                     http://retromoto1.com/