Planos de Minichopper - Final

http://herreriabalconeriaysoldadura.
com/
MINI CHOPPER PLANS BY

SOLUTION DESIGN
Herreriabalconeriaysoldadura.com
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Frame#2 The Little Tyke (Page 27)
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Frame#1 The Little Stretch (Page 6)
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Frame#4 The Easy Brute (Page 62)

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Frame#7 The Low Boy (Page 104)

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Most Frame#8 The High Boy (Page 116)

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Popular
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Frame#6 The Hulk (Page 90) Frame#5 The Black Widow (Page 74)
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Abaddon 2018 http://herreriabalconeriaysoldadura.com/
http://herreriabalconeriaysoldadura.com/
Designed By Solution Design (Design Images not to be used without written permission)
P.O Box 10, Cottam On, N0R 1B0
More info at www.minichopperplans.com
Need To Know How?

Need To Know NOW?
Then check out the world’s largest mini chopper resource
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on the web!
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HardCoreMiniChoppers.com
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Here’s a small sample of the topics you can learn from and
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participate in:
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• Frame Building
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• Engines
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• Clutches/Torque Converters
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Bodywork / Paint
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• Front ends
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• Electrical
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• Bar Stool Racers & Other Custom Rides

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Some of the most knowledgeable builders in the industry

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call the Hardcore Mini Chopper Forum home….shouldn’t

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you?
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Welcome to Hardcore Mini Choppers

http://herreriabalconeriaysoldadura.com/ 2
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
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and labor. This will help protect you from being overcharged.
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Tools Required
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• Tube bender
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• Welder, (I use a small Lincoln 135t portable welder)
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• Drill
• Wrenches, sockets, grinder, screwdrivers, hole saw, etc.
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Where to Begin
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• I started by building the frame, bending the necessary tubes to create the main
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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
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be sure the position of the handlebars; foot pegs and seat fit my nephew.
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•
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Make sure the engine and clutch are aligned straight with the rear sprocket. This
is critical to smooth operation.
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• Make sure the rear tire is also aligned straight. I used a make-shift wooden jig to
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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.
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• 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
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without brakes.
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• 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
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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
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may have needed.

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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.
P.O Box 10, Cottam On, N0R 1
Disclaimer and Limitation of Liability
THE ENTIRE RISK AS TO THE QUALITY AND

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

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INACCURACIES IN, OR DESTRUCTIVE PROPERTIES

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OF ANY MATERIALS, MANUALS, INFORMATION

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READ THE FOLLOWING

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ENGINES, AND THE EQUIPTMENT THEY DRIVE

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ARE AND CAN BE VERY DANGEROUS TO

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OPERATE. THEY ARE ALSO DANGEROUS TO

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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.
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!!!!!!!!
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Good professional welds are important!! Do not compromise
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safety!!!!!
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When welding the frame, tack it first!!!! You may want to change
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the frame to fit your needs and a tack can be easily removed!
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Build the jig; it is well worth the extra time. It will ensure the
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frame is straight and accurate
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Ebay has some great deals!!!!!!!!!!!! Shop around for the best
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prices!
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Be sure you have brakes! Resist the temptation of that first ride
unless the bike is complete.
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Take your time!! Do not cut corners!! You will end up with a
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much better final project

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Be sure you know how to operate the required tools. If you don’t,
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seek the assistance of somebody who does. This project can be a

great learning tool.
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Wear all necessary protective clothing when working with

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grinders, welders, and other power tools.
Always wear safety glasses when working with ANY tools.
Frame Bill Of Material
Item Name Description Purchased Fabrication Quantity

Req’d
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.
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Front gusset See detail Yes Online links
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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
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Front End Bill Of Material
9. Front tire mount brackets See detail Could be either Online links
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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
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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
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16.
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Engine Drive Train Bill of Material
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18. 3.5hp - 6h.p side shaft engine I used a 5hp Tecumseh Yes Online links
19. Option #1 standard clutch & jack See page Yes Online links
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shaft set-up
20. Option #2 belt driven torque- See page Yes Online links
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converter set-up
21. Chain length to suit option 1 or 2 See page Yes Online links
Online links
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Rear Wheel Bill Of Material

22. Axel hangers See page Yes Online links
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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
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frame See page Yes

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Or
15-6.00-6.00 for medium tire frame
27. Rear Rim 4 bolt See page Yes Online links
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28. Rear disc See page Yes Online links

29. Rear disc hub See page Yes Online links
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30. Rim Hub See page Yes Online links

31. Rear sprocket See page Yes Online links
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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
P.O Box 10, Cottam On, N0R 1B0 (Not To Be Resold Or Circulated)
Mini Chopper #1 The Little Stretch
MEDIUM TIRE FRAME SERIES
REAR TIRE SIZE 15 X 6.00 –6

FRONT TIRE 16” BICYCLE
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ENGINE SIZE 2-6.5 HP
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Suitable for riders who may want to convert their conventional mini bike into a mini bike
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chopper .If you have never rode a stretched-out mini bike, you might be better off
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moving on to the next frame - “The Little Tyke”
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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”
Medium Tire Frame Bill Of Material
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FRAME B.O.M
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Detail # Material Wall Thickness Length Required

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1 1.0”Dia D.O.M .083” 34.0”

2 1.0”Dia D.O.M .083” 26 3/4”
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3 1.0”Dia D.O.M .083” 38.5”

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4 1.0”Dia D.O.M .083” 38.5”

5 1.0”Dia D.O.M .083” 12 21/32”
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5a 1.0”Dia D.O.M .083” 12 21/32”

6 1.0”Dia D.O.M .083” 20 7/16”
7 1.0”Dia D.O.M 083” 18.5”
8 (3 Required) 1.0”Dia D.O.M .083” 9.0”
9 1.0”Dia D.O.M .083” 10 3/32”
10 1.0”Dia D.O.M Note***.120” 6 1/4”
COPYWRIGHT 2002, SOLUTION DESIGN 8

NOT TO BE RESOLD OR CIRCULATED
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

• One 75 degree bend with a 15 degree tube notch
• Bend radii is 3.5”
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FRAME DETAIL #4

• 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

• One notch and minor grinding to match to center frame tube
• (See 3D View for more info)
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FRAME DETAIL #5a

(See 3D View for more info)
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FRAME DETAIL #6

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FRAME DETAIL #7
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FRAME DETAIL #8

• 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”

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FRAME DETAIL #10
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• Use plate steel 3\16” thick
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• 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
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• 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
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This is the most important step in building

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your frame, this jig will ensure the frame is

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assembled straight and accurate

Medium Tire Frame Jig Bill Of Material
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Frame Assembly Information
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Clamp or screw axel hangers in position, then tack weld
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Weld detail 1, 2 & 10 together to make a sub-assembly

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Finish the frame by measuring to be sure the frame details are in

their proper position

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
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may run into problems and find you would like to move some of the frame
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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
ENGINE 2-6.5HP
Suitable for young riders and smaller engine sizes (2hp to 6.5hp).
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One of the benefits of a frame this size is the availability of parts. Most of these parts can
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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.
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A GREAT
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BEGINNER
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BIKE
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FRAME DETAIL #1

• One notch required
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FRAME DETAIL #2A & 2B

• One notch required per detail
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FRAME DETAIL #3 & 4

• One notch required per detail
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FRAME DETAIL #5
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• Two notches per detail

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FRAME DETAIL #6

• Notch 2 Places
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FRAME DETAIL #7
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ENGINE MOUNT PLATE DETAIL
• Use 1\8” mild steel plate
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FORK DETAILS
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• 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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• 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

Mini Chopper #3 The Rat Fink
WIDE TIRE FRAME SERIES
REAR TIRE SIZE 18.5 X 8.5 –8 OR 205-50-10

ENGINE SIZE 2-9HP
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“Riding mini bikes with stretched-out forks requires skill and balance. Learn the basics
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Wide Tire Tube Frame Bill Of Material
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FRAME B.O.M
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1W 1.0”Dia D.O.M .083” 38 11/32”

2W 1.0”Dia D.O.M .083” 30 11/16”
3W 1.0”Dia D.O.M .083” 43.5”
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4W 1.0”Dia D.O.M .083” 43.5”

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5W 1.0”Dia D.O.M .083” 17 5/32”

5aW 1.0”Dia D.O.M .083” 17 5/32”
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6W 1.0”Dia D.O.M .083” 20 7/16”

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7W 1.0”Dia D.O.M Note*** .120” 23.0”

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8W (3 Required) 1.0”Dia D.O.M .083” 12.5”

9W 1.0”Dia D.O.M .083” 11 1/8”
10W 1.0”Dia D.O.M Note***.120” 6 1/4”

FRAME DETAIL #1

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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

• One 75 Degree bend with a 15 degree tube notch, Bend radii is 3.5”
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FRAME DETAIL #4

• 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

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FRAME DETAIL #5a

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FRAME DETAIL #6

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FRAME DETAIL #7
Tube length 23.0”, Diameter 1.0”, Wall thickness .083”
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FRAME DETAIL #8

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FRAME DETAIL #9
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FRAME DETAIL #10

Tube length 6 1/4”, Diameter 1”, Wall thickness .120”
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ENGINE MOUNT PLATE
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• Use 3\16” thick plate steel

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• 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
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• Transfer bearing mount holes to ensure proper pattern
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• 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
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This is the most important step in building your

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frame; this jig will ensure the frame is assembled

straight and accurate

Wide Tire Frame Jig Bill Of Material
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Weld detail 1, 2 & 10 together to make a sub-assembly

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

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
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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
REAR TIRE SIZE 18 X 8.5 –8 OR 205-50-10

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ENGINE SIZE 2-9 HP
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“Riding mini bikes with stretched out forks requires skill and balance. Learn the basics
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FRAME DETAIL #1

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FRAME DETAIL #2

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FRAME DETAIL #3
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• Tube length 12 1\2”, Diameter 1.0” Wall thickness .083”

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FRAME DETAIL #4
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FRAME DETAIL #5
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FRAME DETAIL #6

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Engine Plate Detail
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• 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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• Load details 3, 4, & 5 into the jig

• Weld detail #1 to the steering neck outside of the jig
• 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

Mini Chopper #5
The Black Widow
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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
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Engine Mount Plate Detail

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• 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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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
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Black Widow Jig Bill Of Material
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Weld detail 1 & 9 together but measure to make sure it is centered
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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

Black Widow Frame Side Profile
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Black Widow Rear Profile
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Mini Chopper #6 The Hulk


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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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Detail #2 & #3
• For this detail use a 1” Diameter .083” Wall D.O.M Tube 36 1\8” long
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• Detail #2 and #3 are the same
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Detail #4 & #5
• For this detail use a 1” Diameter, .083” Wall D.O.M Tube 49 1\8” long
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
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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
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• For the engine mount plate use a 12” X 7 3\4” plate 3\16” thick
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The HULK JIG
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The Hulk Bill of Material
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Weld detail 1 & 9 together but measure to make sure it is centered

er
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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

The Hulk Frame Side Profile
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The Hulk Rear Profile
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Mini Chopper #7 The Low Boy


ENGINE SIZE 2-9 HP
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FRAME DETAIL #1

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The Low Boy Side Profile
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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

FRAME DETAIL #2 & #3

• Two bends required
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Detail #4
• Make two notches to match frame
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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 sure the notch at the steering neck matches the neck tube diameter
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• For the engine mount plate use a 12” X 7 3\4” plate, 3\16” thick
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The Low Boy Side Profile
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• Once complete remove the frame, weld completely, and then move onto the drive
train

Mini Chopper #8 The High Boy


ENGINE SIZE 2-9HP
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FRAME DETAIL #1

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• Two bends required
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• One bend & two notches required

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FRAME DETAIL #6
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• For the engine mount plate use a 12” X 7 3\4” plate 3\16” thick
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FRAME DETAIL #7

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Detail #8 & #9
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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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• Once complete, remove the frame, weld completely, and then move onto the drive
train

MINI CHOPPER FRONT END PLANS FOR BOTH
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MEDIUM AND WIDE TIRE
FRAMES
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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 REQ’D
7 PLATE STEEL SEE DETAIL SEE DETAIL

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
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THE INDUSTRY STANDARD. MOST HAND LEVERS AND CONTROLS ARE
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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.
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FRAME DETAIL #3A & 3B STEERING NECKS

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• The most common steering neck is a 1 5\8”, .120”wall piece of D.O.M tube” (this
will require two bearings to be pressed-in). This is the best way to go!
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• 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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• 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
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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
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• You may also choose to replace detail 3 with a 1 5\8”, .120 wall D.O.M tube; this
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will allow you to use bearings in the neck. You will have to adjust the tube
notches on the other frame components.
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Option #2
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Jack Shaft Drive

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5
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6
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1 Clutch More Info

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2 Locking collar More Info

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3 Bearing More Info

4 Jack shaft More Info
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5 Sprocket More Info

6 Locking collar, bearing, Flangettes More Info
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7 1” Diameter axel shaft & locking key More Info

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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.

Jack Shaft Mounting Info
Medium Tire Frame
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For the chain to clear the frame you will need to mount the
jackshaft mount tabs above the base of the frame

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 engine’s shaft.
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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
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bracket to the frame. This will act as a support and guide to the chain
and keep it from rubbing on the frame.
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Comet Torq-A-Verter TAV2-30

Live Axels Continued
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Above you have a complete live axel set up

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Rear Brakes
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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
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set-ups and friction bands.

If you are planning to use a mechanical brake system, I suggest the rotary
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brand mechanical disc brake part# 04-9306.

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

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
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Rear Drum Brake
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Rear Drum: There is also a drum style brake available. I have
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Caliper Type Disc Brake

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The caliper brake system shown below rides on the rear drive
sprocket. This unit can be mounted by making a custom
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bracket.
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Chain Guard
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Don’t forget safety! Be sure to protect

your little riders by adding a chain guard.
This unit is available at mfgsupply.com

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

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

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
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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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High Quality Parts

TRIPLE TREES
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AXEL HANGERS
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FRONT TIRE MOUNT BRACKETS
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AVAILABLE AT
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https://www.minichopperplans.com/

Online Part
Suppliers
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U.S Parts Suppliers
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www.bmikarts.com
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www.gokartsupply.com
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www.cvmkarts.com
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http://www.georgessales.com/
www.johnsgokarts.com
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www.jsesc.com
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www.crosstec.com
www.minibikekits.com
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Canadian Parts Suppliers

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www.gokartexpress.com
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www.idealkarts.com
Thanks & Good Luck!

Other Projects Available From
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Solution Design
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1.5” Diameter tube bender plans
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1.0” Diameter tube bender plans
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6’ X 10’ Utility trailer plans

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2 Seat Dune Buggy Plans

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4 Seat Dune Buggy Plans

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Mini Bike Plans

Be Sure To Sign Up At
Check out the world’s largest mini chopper resource on
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the web!
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Here’s a small sample of the topics you can learn from and
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participate in:
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• Frame Building
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• Engines
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• Clutches/Torque Converters
•
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Bodywork / Paint
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• Front ends
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• Electrical
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• Bar Stool Racers & Other Custom Rides

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Some of the most knowledgeable builders in the industry

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call the Hardcore Mini Chopper Forum home….shouldn’t

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you?
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Welcome to Hardcore Mini Choppers

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Planos de Minichopper - Final

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Planos de Minichopper - Final

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MINI CHOPPER PLANS BY

Frame#4 The Easy Brute (Page 62)

Frame#7 The Low Boy (Page 104)

Most Frame#8 The High Boy (Page 116)

Need To Know How?

• Bar Stool Racers & Other Custom Rides

Some of the most knowledgeable builders in the industry

call the Hardcore Mini Chopper Forum home….shouldn’t

Welcome to Hardcore Mini Choppers

may have needed.

Use only D.O.M tube.

Disclaimer and Limitation of Liability

THE ENTIRE RISK AS TO THE QUALITY AND

FAILURES, ERRORS, OMISSIONS, OR OTHER

INACCURACIES IN, OR DESTRUCTIVE PROPERTIES

OF ANY MATERIALS, MANUALS, INFORMATION

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

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

much better final project

seek the assistance of somebody who does. This project can be a

Wear all necessary protective clothing when working with

grinders, welders, and other power tools.

Always wear safety glasses when working with ANY tools.

Frame Bill Of Material

Item Name Description Purchased Fabrication Quantity

Rear Wheel Bill Of Material

23. Bearing cages See page Yes Online links

frame See page Yes

28. Rear disc See page Yes Online links

30. Rim Hub See page Yes Online links

32. Rear sprocket hub See page Yes Online links

Custom Parts to Suit Your Taste

REAR TIRE SIZE 15 X 6.00 –6

NOT SUITABLE FOR BEGINNERS

Detail # Material Wall Thickness Length Required

1 1.0”Dia D.O.M .083” 34.0”

3 1.0”Dia D.O.M .083” 38.5”

4 1.0”Dia D.O.M .083” 38.5”

5a 1.0”Dia D.O.M .083” 12 21/32”

COPYWRIGHT 2002, SOLUTION DESIGN 8

• Tube length 34.0”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 9

• Tube length 26 3/4”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 10

• Tube length 38.5”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 11

• Tube length 38.5”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 12

• Tube length 12 21/32”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 13

• Tube length 12 21/32”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 14

• Tube length 20 7/16”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 15

• Tube length 18.5”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 16

• Tube length 9.0”, Diameter 1.0”, Wall thickness .083”

COPYWRIGHT 2002, SOLUTION DESIGN 17