How to Build a Chopper Motorcycle
Most motorcycle enthusiasts trace choppers back to World War II vets coming home from tours of duty, particularly in Europe, who wanted to rekindle some of the two-wheeled thrills experienced overseas. However, the US manufacturers...
Method 1 of 3:
Modifying a Motorcycle
- Take advantage of an already-working motorcycle and chop it to taste.
- Running the original motorcycle allows you to maintain registration or licensing more easily, as you are running an original manufacturer's vehicle with their registration numbers.
- Ride the motorcycle, get a feel for what you like "as is" and what you want to modify.
- Modify any original parts, taking advantage of the original mounting brackets and hardware.
- Add or subtract parts as time and money allow, while keeping the bike in running order, to minimize down time and prolong your riding enjoyment.
- Purchase and customize the rolling chassis. A rolling chassis includes the frame, both wheels, the front forks, handlebars and clamps that hold the bars to the forks, and customize with body work and drivetrain.
- The registration numbers belong to the frame, so you can start either with a salvage project from an original manufacturer, or with an aftermarket manufacturer specializing in rolling frames.
- Install the drivetrain of your choice.
- As the wheels, front suspension and frame already work together as a unit, you know what drivetrain will fit the basic dimensions of your bike, lessening the guesswork involved.
Method 2 of 3:
Building a New Kit Bike
- Combine the challenge of building a new chopper from the ground up with the convenience of sourcing all the major components from one manufacturer.
- This option may appeal to first-time builders in particular, as all the parts are designed and built to fit together; the manufacturer can address problems or warranty issues.
- Prepare for added time, effort and space.
- Have a well-lit, uncluttered space you can dedicate solely to the project. You will be building in stages, leaving you with a partially assembled chopper in this space for a long period of time.
- This option may cost the most up front, as you will be purchasing most or all the components of a new motorcycle at the same time.
- Have a well-lit, uncluttered space you can dedicate solely to the project. You will be building in stages, leaving you with a partially assembled chopper in this space for a long period of time.
Method 3 of 3:
Building With Salvaged Parts
- Start with one object, such as a gas tank, carburetor or set of wheels, and build a custom chopper around the theme imagined from that part.
- Usually only advanced mechanics take on this option, as it entails a lot of time, resources and skill. Experienced chopper builders also understand what works or fits together and what doesn't.
- Work with a trusted source for parts.
- Look for a large motorcycle shop or even a junkyard that has a dedicated area for motorcycles as a starting point, both as a parts source and a place to turn to for advice.
- Develop a solid relationship with a speed shop.
- Get mechanical assistance in building or rebuilding drivetrains, creating or modifying custom body parts and painting or plating bare metal.
Update 24 March 2020
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