![]() ![]() I only discovered this later during a test ride when a wheel's spokes were rubbing against the inner side of the fork tubes. IMPORTANT: I made a mistake when I welded my dropouts - I placed them right in the centre of the tube - I should have moved them closer to one edge. I used a magnetic mount to hold the drop-out to the fork. (Pic 6) Next, we need to weld the drop-outs to the forks. Keep trying to fit the wheel axle into the slots until they just fit. ![]() Your aim here is to cut a slot just big enough for the wheel's axle to fit snugly. Take your time here - don't cut too much of you'll risk the wheel popping out. Clamp the two pieces together and cut out the slots for the wheel axle.This way, you can be sure that when you use an angle grinder to cut the slots, both slots will be identical. Remember, the straighter the surface, the better the join will be. Pic 4 Use the grinder to make the edges neat. I aligned the drop-outs in a clamp and used the grinder to get their edges identical. Angle grinding is never exact, so the drop-outs were not exactly the same. Use an angle grinder to cut out two pieces from the steel to form the drop-outs. This will give an indication of the size and shape of the piece to cut out. Overlay one of the existing fork's drop-outs onto the steel to be cut. I used some scrap steel plate, about 3mm thick. There's no way of attaching them to a wheel, so we need to make some drop-outs. Above all, enjoy building and don't give up! Read on for instructions on how I did it, and the mistakes I made along the way. *Access to a pipe bender - you may need this if your angles change significantly and you don't want to cut the extension tubes at an angle. ![]() *New chains - if you're extending the frame significantly, the chain length will also increase. I had some 1.4mm thick sheet steel which is perfect for the plates I made. Butt welding tubes of the same diameter is more difficult and will not be as strong unless your an expert welder (and I'm not!). The diameter of this tubing should be either slightly smaller than the existing frame tubing (to fit inside the cut tubes) or slightly bigger (to fit over the tubing). *Steel tubing to extend the frame after chopping. These need to be quite heavy gauge as the forces involved will tend to bend the tubes. *Welder (I used a gasless MIG welder - a Clarke 105EN) *Steel tube(s) for the forks. I took a 25 year old Raleigh Wisp ladies racing bike and converted it to something a bit out of the ordinary. I've recycled as many parts as possible, and used scrap materials when I could. The main inspiration for this came from AtomicZombie and Koolkat's instructables. This is an instructable on how to build a chopper bike on a budget. ![]()
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