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Final Assembly
Time to bolt it all together
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Frame Setup: With the frame and swing
arm painted, it is placed onto the lift to start the final assembly. This
will go quickly now that all the parts and sub-assembles have been previously
installed during the hot mock-up phase.
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Triple Tree and Fork Tubes: The
frame is carefully tied to the lift table and the 7* rake triple tree
is installed into the frame neck. The fork tube assembly is then slid
up into the tree. Masking tape is placed on the tree to prevent scratching
the new paint.
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Front Wheel: The front wheel is installed
and is placed into into the bike vice.
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| Swing Arm:
The swing arm is now attached to the frame (don't forget the belt). A chrome
splash guard is attached to the front of the swing arm.
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| Engine
and Transmission Install: The lift is dropped to floor. Masking
tape and bubble wrap is place onto the frame where the engine and transmission
might bump into. The engine is carefully placed into the frame followed
by the transmission and transmission plate. |
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| Rear Wheel:
The rear wheel and air ride suspension is installed and aligned to the transmission.
The axle covers are placed over the end of the swing arm and the license
plate is attached to the axle. |
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| Primary
Drive/Starter/Oil Pan: The clutch, compensation sprocket and
drive is installed. The starter and oil pan are placed in and the oil lines
are connected. |
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| Handle
Bars and Controls: The handle bars are attached to the tress.
All the cabling was connected together from the hot mock up, this makes
the assembly very fast. The front brake is attached to the wheel, clutch
line is attached and throttle cables are connected. |
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| Sheet Metal:
The front fender, rear fender and tank are attached to the bike. Man....
Its looking really nice. The cosmetic tank extension look awesome. |
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| Wire Harness:
With the rear fender attached, we can add the wire harness. The fuze panel
is built into the fender, the is basically no room for any electronics on
a chopper... |
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| Seat:
We attached the seat and take it off the lift. Roll it out into the driveway,
add about 1 gal of gas... Done... She fires right up !!! |
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Completion of the Final Assembly:
The bike has come along way over the last 19 months. This has been one
of the most satisfying engineering projects that I have ever worked
on no time tables and freedom to create. Its been an overall great learning
experience.
© 2008 JH Choppers. All Rights Reserved
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