Homemade bicycles are necessary. Making a bicycle with your own hands. Final assembly of the bike

With the onset of warm weather, they become increasingly relevant. bicycle rides on fresh air. It’s nice to see whole families riding their iron friends around the park area and bike paths on their days off. promotes health, general physical development and is extremely useful, even if it is not strenuous sports training.

The variety of bicycle transport on the modern market is very large and can satisfy the most demanding buyer, both in functional terms and in cost. Moreover, the price for individual copies can reach several thousand dollars. There are a huge variety of bicycles various types, for example: mountain, track, sports, city. Stand as a separate group homemade bicycles. They are distinguished from each other by various parameters of weight, design, wheel sizes, number of speeds, etc.

No need to buy a bike

An alternative to buying a bicycle is to make it yourself. Homemade bicycles are very common and are distinguished by their original design. But to implement such an idea, you need to be patient and have certain professional skills and tools. And it’s best to have access to a workshop equipped with the necessary tools and equipment. Assembling homemade bicycles from ready-made parts will not be difficult; anyone can do it.

How to make a bicycle?

In order to assemble you will need a detailed drawing. You can draw it yourself, but it is best to use ready-made options, which are not difficult to find if you wish.

Using a ready-made drawing will help you avoid possible mistakes when assembling your vehicle. It will be impossible to ride a bicycle made according to a technically incorrect drawing. In addition, if the balance of elements is incorrectly calculated, the load on some parts and assemblies will be increased, which can lead to their accelerated wear. And soon the most critical moment may come when vehicle will fail or fall apart. There is a very high risk of injury and disfigurement if a breakdown occurs while the bicycle is being used.

Can't do without shopping

It is worth understanding that some mechanisms, such as chains and wheels, cannot be made at home, or even in a workshop. In any case, they will have to be purchased from finished form. In this case, it is worth paying attention to the material from which the wheel rim and spokes are made. The tire must be selected taking into account the operating conditions of the bicycle. If you plan to drive in quiet urban conditions, then regular city tires will do. If you plan to drive aggressively or operate in rough terrain, you will need tires with reinforced tread to improve the wheel’s grip on the ground. Homemade ones are very popular and original nowadays. tricycles. Immediately before assembling the bicycle, you should carefully study the drawing and determine the exact sequence of actions.

The stronger the metal, the more durable the bike

To produce the frame, you will need tubes of various diameters made of durable metal. It will not be superfluous if the metal surface is treated with an anti-corrosion compound. This will extend the life of the bike.

According to the drawing, you need to make all the elements of the frame and connect them together using After the frame is ready, it should be checked for defects and, if necessary, all the nuances should be finalized.

When making a fork, you will need to use special pressing equipment. You can use devices and tools designed for forging metal for these purposes. When the fork elements and frame are almost ready, you need to drill all the necessary holes in them for attaching wheels, sprockets and pedals.

Next you need to make the steering wheel, saddle and pedals. If these parts are left over, they can be repaired or simply brought back to normal if they are in good technical condition. The chain, wheels and brakes must also be checked for serviceability and repaired if necessary. Problems can arise due to leaky spokes, lack of lubrication on the brake mechanism, and poor-quality bicycle chain links.

Homemade bicycles, or rather, their parts, can be painted by first covering them with a primer. Even the thinnest layer of paint will protect the metal from corrosion. This will help maintain the appearance of the parts in proper condition.

Assembly and running-in

If all the components are prepared, then you can attach them to the frame for a preliminary assessment of the technical suitability of the assembled vehicle. The first thing you should pay attention to is the quality and straightness of the bike, the ease of pedaling, the functionality of the brakes and other, less significant nuances.

If the ride is not satisfactory or is impossible without some effort, then you need to understand the existing inconsistencies, correct them and carry out further tests. If all parts and components are in good condition, the bicycle should be completely disassembled for painting.

Buy and collect

If there is no particular desire to resort to such a complex option, then it is easier to purchase ready-made components and assemble bicycles with your own hands, adapting them to your needs and wishes. You can build a lightweight version using a titanium or cheaper aluminum frame. It can be equipped with any components of appropriate quality and value. Possible to design Homemade option such transport will be the most convenient and practical. If any component or component fails or simply no longer suits its characteristics, then it can be replaced with a new one without any problems.

It is worth remembering that frequent use of a bicycle instead of a car not only has a positive effect on health, but also improves the environmental situation.

These designs are similar to both cool motorcycles and their “big brothers”, but longer. You can buy them in a store or make a bicycle with your own hands.

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From motorcycles they took a long frame and fork, and a large steering wheel. Thanks to the unique design, the center of gravity was shifted, making the vehicle more rolling. Thanks to this, the chopper can easily ride even on bumpy asphalt.

In Russia they are last years are gaining popularity.

Additional advantages include the following:

exquisite appearance;
unique style;
high comfort;
wide tires, allowing you not to feel the unevenness of the surface;
the possibility of electrification and turning it into a bicycle moto;
affordable tuning;
an unforgettable driving experience.

On the site http://megavel.ru/category/velosipedy-choppery/ You can get acquainted with the models and the price, which cannot be called low. How to be? You can do it yourself, and for reasonable money.

If you strictly follow the instructions below, which use parts from old bicycles and scrap materials, it is quite possible to make a vehicle with your own hands. It will turn out no worse than what the retail chain offers.

An old women's bike from the Wisp Raleigh brand is suitable for making a chopper, which will turn into a wonderful cruiser.

Required materials and tools

So, in order to make a chopper with your own hands, you need:

welding machine, type Clarke 105EN;
donor bike;
durable steel pipes for making forks and extending the frame. The diameters of the pipes for the frame are selected so that two pipes of different diameters can be welded (this is simpler and more reliable than welded pipes of the same diameter),
sheet steel 1.4 mm thick for hopper plates;
2 new chains that will be required for the enlarged frame. They need to be connected together;
pipe bending machine. It is needed so as not to cut the elongated pipes at an angle, but to bend them, significantly changing the angles of the frame.

When you have prepared the materials and tools, you can start making a bicycle with your own hands, turning an ordinary model into a chopper.

Fork manufacturing sequence

Step 1: Which model to choose?

U racing bike Raleigh Wisp, taken as a basis, the frame has an unusual shape: the top tube goes from above to rear hub, which is only to our advantage. It is advisable to preserve this feature. The seat can be installed on a double top tube.

You need to start making a structure with your own hands with a fork.

Step 2: Chopper Fork

First you need to choose the right one.

We start making a bicycle with our own hands by dismantling the old one, for which:

remove the steering wheel with stem, steering column and unscrew the fork;
We position the bike in such a way that the steering column is at the optimal height while riding, without worrying about the angles - they are not taken into account at this stage (see picture above). We measure the required length of the fork, i.e. distance between the front wheel axle and top part steering columns. Approximately this is 122 cm. The size is decent, but this is for a chopper - a long bicycle! We select a steel pipe, 2-2.5 meters long;
We cut the pipe in half using an angle grinder, grind the ends on the grinder and place the pipes vertically.

Step 3: Fork Dropouts

For now, the fork consists of two pipes. In order for it to take on a normal appearance that allows you to install a seat, you will need two strong dropouts.

To make them with our own hands, we stocked up on sheet steel. The thickness of the plates should be approximately 3 mm.

The photo shows how the dropouts from a bicycle fork need to be applied to a steel plate to outline the outline for further fabrication. The blanks are cut from steel using an angle grinder.

The required accuracy should not be expected. Therefore, after the blanks are cut and brought to the right size, clamped in a vice.

The edge must be processed carefully, since the contact between the surface and the wheel depends on this.

The nest is cut out carefully so that it is not large and this does not lead to the wheel popping out. The axle should sit tightly in the socket. Do not allow any play (pic below)!

When the dropout blanks are ready, they are welded to the fork using a magnetic holder.

Important: There is no need to place the dropouts in the center of the pipe - they should be welded closer to the edge so that the spokes do not rub against the pipe.

At first, it is better to simply “grab” the dropouts by welding, and weld them securely after making sure that everything is installed correctly. At this stage, the time spent earlier on processing the edges pays off handsomely.

Step 4: make the top for the fork

For now, the future fork consists of two pipes to which dropouts are welded. This means it’s time to cut a thread on the top, which will require nuts with washers and M10 bolts. In any store such a kit is cheap.

You need to assemble the structure with your own hands, as shown in the figure, by welding each of the faces of the nut to the washer.

The bolt is no longer needed, so it can be unscrewed.

It’s time to weld the washer with the welded nut to the pipe (future fork)

Step 5: DIY chopper fork assembly

At this stage there are two pipes, to which dropouts are soldered on one side and nuts on the other. To further make the fork with our own hands, we cut off the old “leg” and make the base as flat as possible. We use cardboard as a template, on which we draw a semicircle around the pipe of the new fork.

Using an angle grinder, we cut out the crown for the new fork according to the template. We do this very carefully so that the shape is as correct as possible.

To determine the width of the fork, you need to attach a wheel to the dropouts. Having placed the rod with the crown between the pipes (it should stand level if everything is done accurately), we cut out three holes from another cardboard into which the pipes will go.

We will use this template with three holes to make the base and top plates, after cutting the cardboard and giving it an aesthetic shape.

We start making a base plate with our own hands by cutting it out of a 1.4 mm thick steel sheet according to a template. On the steel we mark two holes for the fork legs and cut the sheet as in the photo.

After this, we weld the finished base plate to the fork crown. It is important to do everything carefully, avoiding contact with molten metal on the bearing race.

Now you need to make a stem, for which you can cut off the existing stem top part or do everything from scratch if there is a steel pipe that matches the inner diameter of the fork rod. To do this, the pipe is cut at an angle of 45 degrees using the same angle grinder.

Now the pipe is shortened so that it fits the wedge and rod bolt. This completes the production of the takeaway. If you are using an existing stem, skip this step.

After the new stem is placed on the fork stem, place the stem and crown between the fork legs again, having someone hold it all down, or securing the assembly with a belt. It is important that the top nuts are located one inch below the top of the fork. If everything is centered, the plate needs to be welded to the fork.

Step 6: Second stage of making the fork

We have two pipes that are welded to the crown and stem, which means it's time to connect everything together. This requires a top plate. It is done by analogy with the basic one and the existing cardboard template. We mark on the sheet of steel the centers of the stem bolt and two legs. If bolts with a diameter of 10 mm are used, then a 15 mm drill will be needed to drill a hole in the center of the fork, since washers will be used during assembly.

The top plate is ready and needs to be bolted to the top of the fork.

The bolt retaining clamp will be discussed below. The fork is ready.

A wheel is attached to it and installed on the chopper, as shown above.

Now, to make riding comfortable, you need to upgrade the frame. And this is the next step.

Frame making

Step 7: First Stage

To cut the frame, it must be turned over and secured.

After some actions, the carriage became closer to the front of the bike. Now the frame needs to be lengthened.

We set aside the double top tube, which will look good on a chopper.

It is better to make a mock-up of the future frame before starting assembly in order to correctly place the wheels and determine the desired height of the frame. To do this, it is enough to support the carriage and lengthen the frame using thin pipes.

In the variant under consideration, the top tube turned out to be located a little low, so it had to be bent so that the saddle was on required height. This must be done carefully so as not to break the pipe.

Well, if this happens, welding will help correct the situation.

If the design is satisfactory, you can move on to the next step, in which the frame is lengthened using steel pipes placed in the gap between the carriage and the two pipes running from the seat tube down.

This is where you will need a model to use to measure the length of two pipes. Because the angle of the down tube changed, it was necessary to make a bend near the bottom bracket. A pipe bender was used for this.

For now, the seat tube remains dangling, not secured to anything, so that’s what needs to be addressed.

We will again use the cardboard as a template to make another plate of sheet steel, which will be welded to the top of the horizontal pipes under the seat tube.

So the strength of the connection between the new two pipes and the rear ones will be increased. After this, the seat tube is welded to the plate.

The top tube was left dangling.

Another plate made of steel, and a socket made with a grinder in the seat tube, into which it must be inserted and welded, thus increasing the strength of the connection and reducing the load on the weld.

All that remains is to weld the two upper pipes to the steel plate, and they will stop hanging around.

Step 8: Stage two of making the frame

All that remains is to strengthen the frame structure. This can be done using another steel pipe, welding it between the carriage and the top pipe. This makes it possible to change the location of the seat tube, which is currently directed towards the rear of the frame.

Again, using the template, we make a plate and weld it to our pipe: lightly at first, and after selecting the angle, finally. The pipe should not touch the carriage axle. It should not go deep into the carriage.

This is what a finished frame looks like, made in-house for a chopper.

Step 9: How to make a saddle for a chopper?

A plank structure is suitable. In order to make it soft, we use foam material, and for aesthetics we use leather.

The two boards are fastened together using bolts. In the bottom you need to drill two holes through which the seat will be attached to the plate. It must be securely fixed using bolts and nuts.

A construction stapler will help secure the upholstery material with staples.

The leather is also stapled to the seat.

The procedure for making the steering wheel

Step 10: Handlebar for a Homemade Chopper

There are three ways to install it:

install the old one. But it may not fit the configuration (ram's horns, for example);
do it yourself if there are steel pipes left. You can bend it with a pipe bender or cut it and weld it into the desired shape;
choose one that suits the shape.

But first you need to make or select a donor lock. If one is found, mounting is not difficult.

This is shown in the photo.

Finally, you need to install the fastening clamps on the previously made top plate.

Weld them to the plate.

Also weld the clamp and insert the steering wheel into the mount. The steering wheel mount is adjustable.

Reliable brakes

Step 11: Brake System

If you planned to use wheels from a donor bike, there may not be any problems. If the wheels, for some reason, are not satisfactory, and you want to replace them with more stable ones, for example, you need a different suspension.

When carrying out welding work, be sure to cover the tire with a damp cloth to avoid damaging it.

Before cooking completely, check the operation of the clamp brake again.

This is what it should look like. The brake lever will work just fine from an old bicycle.

Assembly and testing

Step 12: Final Assembly and Testing

The difficult but interesting work of making a chopper has come to an end. All that remains is to carry out tests. Simpler bike convert it to single-speed, for which you will need to buy a single-speed adapter.

They can easily replace the old gear system. It was already mentioned at the beginning that a chopper bicycle is much longer than a regular bicycle, so you will need two chains. They are connected together.

Step 13: Completing the Assembly

A self-made bicycle is disassembled to remove welding spatter, and the fork and frame are painted in the preferred color. Bearing rings must be protected from paint during work, like other threaded connections.

It is more correct to apply the paint in a thin layer - this way you will make the paint even, without drips. It is better to then apply a second coat of paint.

Step 14: Possible Design Changes

If the model gets boring, you can disassemble it and make changes to the design, cutting off, for example, back.

Step 15: Align the Back

Then take the rear end of a small mountain bike.

Here again you need an angle grinder to sand down the extra parts of the frame.

Step 16: Correctly installing the extension lower pipes

Two pipes are cut so that they can be welded to the frame, lengthening the latter.

Step 17: Summary

Having welded and painted two long pipes, we assemble the bicycle, which should look like in the photo above: this model is equipped with a foot brake rear wheel, eliminating the need for levers, cables and the old rear brake.

Try making a bicycle with your own hands - it's an exciting job and no less exciting rides!

Video: DIY chopper

Every cyclist should be able to independently troubleshoot various problems and also maintain their bike. If you don't have it at hand the right tool from the standard set, simple homemade devices that can be easily made with your own hands at home will help.

Homemade bicycle spoke key

If the geometry of rotation of the bicycle wheels is disrupted ("eights" appear), it is better to solve the problem here and now, without delaying until better times. To eliminate wheel runout, you just need to tighten (or, conversely, loosen a little) the spokes. And this is easy to do with a special key. If the factory one is lost, we make a homemade one.

We take a compression nut, which is used for installing water pipes, and using a grinder we make cuts of the required width (the dimensions must first be taken with a caliper). Remove burrs on sandpaper. Works literally for 2-3 minutes.

"Case" to protect the frame stay

At driving fast off-road or when riding on bumpy roads, which are “a dime a dozen” in Russia, the chain hits hard against the chainstay of the bicycle - the part of the frame located under the chain. In addition to the fact that when moving, an unpleasant loud clang of metal is heard, this also causes the paint to peel off, scratches appear, and then corrosion is not far away.

To protect your bike's chainstay from contact with the chain, you can make a simple cover from thick fabric with Velcro for a quick and secure fit. Alternatively, you can simply wrap a thick rope around the frame.

Bike chain cleaning tool

But not every craftsman has an experimental chainsaw on hand. And just for those who have already run out of chainsaws, and the scope for mechanization of everyday life is still very wide, I suggest that you familiarize yourself with the review of homemade products using muscle power. Today we will not consider the great variety of vehicles born from the minds of the inventors of the bicycle - this is a topic for a separate discussion. We will look at stationary solutions.

Perhaps the simplest and most obvious application for a pedal drive is an electric generator. The great Chinese industry produces a great variety of all kinds of generators that can be installed on a bicycle in a few minutes, without even losing mobility:

A generator roller pressed directly against the wheel tire.

A hub-generator installed in the front wheel of a bicycle instead of the original one.

Or even a USB charger that fits directly onto the chain drive.

But, as the reader will correctly grin, these methods are extremely unsporting for our homemade person. Therefore, we take a sports one, or not quite sport bike, a table, two rollers from a dot matrix printer, a car generator, an inverter and some bright paint:

It is assembled relatively quickly, which cannot be said about the following designs:

And if you combine a bicycle generator with a computer, you can spend a couple of hours on the Internet with health benefits.

The next popular use of pedal power surprised me a little. It turns out that washing machines are quite often assembled with pedal traction.

Although it looks like a washing machine, it is already a full-fledged industrial machine for stirring soap:

To grind apples and beans, the following two bicycle grinders were created:

Watering tomatoes in a greenhouse is not a problem when you have a bicycle pump at hand... Or rather, a bicycle pump under your feet:

What does the Chinese woman Kin Min Sal, soy cutlets, cook for lunch? And here the bicycle chopper is indispensable. “It’s a big family,” as the poet said.

In the hot countries of Africa, it is very difficult to supply electricity, and sometimes you just want to drink a glass of cocktail. Not a problem when you have a bike blender:

The hazelnut is certainly hard,
Although walnut too,
However, this unit
They can be easily cleaned by:

In countries North America, the corn shelling machine is probably popular. I couldn’t figure out how she does it from the photo. It is necessary to note the brutality of the design, apparently this is a tribute to the American traditions of industrial design.

I thought it would be simple and simple to supplement the manual drive of the mill with a pedal one:

A compact snow blower will help you quickly clear paths. Of course, if you have such smooth paths.

And in conclusion, I would like to especially mention our fellow countryman - plumber Mikhalych from Chelyabinsk, who designed and assembled a unique spinning rod design that allows you to increase the speed of fishing. In addition, due to the increased diameter of the reel, high torque is achieved and, accordingly, the tension force of the fishing line increases. Unfortunately, the issues of effective braking of the reel when casting gear and reliable fixation of the fisherman on the shore have not yet been finally resolved.

When starting to create bicycles with their own hands, craftsmen should evaluate how often and for what purposes they plan to use homemade bicycles. A homemade two-wheeled design is rather an experiment, an opportunity to prove to myself: I can do more than others, because assembling a vehicle from scratch is a troublesome task. Many parts cannot be made on your own, so you have to run to special stores for such components.

Another important point- understand very clearly what each component of the bicycle is needed for, which components cannot be abandoned, otherwise it will suffer or it will not travel more than 2 m.

Components of a homemade bicycle

Frame

If you have a frame left over from an old, leaky bicycle, great, the main thing is that it is in good condition and free of rust. If there is no frame, it doesn’t matter either; purchase steel, aluminum or titanium narrow pipes.

The basis is a drawing on which all the components of the bicycle are displayed. It is better if the sketch is made in 3D mode on a computer, you can immediately assess the real dimensions of the necessary parts and get an impression of the proportionality of each. Welding remains the preferred method of connecting functional components, if you additionally plan to attach a trunk to the frame or provide recesses for bolts. Holes are also left for bolts for hanging components.

Front fork

It's hard to imagine homemade functioning bicycles without a front fork. If you plan to drive the bike, sliding down the mountain and climbing up, it is better to install a soft shock absorber. You should not mount BMX forks in mountain models - they are too heavy. When making a fork with your own hands, calculate the following parameters:

fork stroke;
method of fixing the brakes;
preferred wheel diameter.

Transmission and brake

Transmission components are selected based on the amount allocated for this part of the bicycle. Experts do not advise assembling the chain with your own hands or creating a speed switch; you will only waste your time, good quality you still won't achieve it. When you come to the store, choose a classic transmission; the placental format has a number of significant disadvantages.

They are divided into rim and disc. If cycling is done in dry weather, rim brake pads are suitable; they are inexpensive and significantly lighten the design. Rim brakes won't withstand extreme travel - use disc brakes. With the latter, riding safety and comfort for the cyclist are ensured.

The wheels, of course, should be bought ready-made, as well as the saddle. If you prefer a sporty riding style, pay attention to hard and elastic saddles that take into account the anatomical features of the cyclist.

It would seem that it would be easier to choose pedals. Beginners in cycling believe that, apart from the classics, designers have not come up with anything else, but they are mistaken. The modernized devices secure the legs tightly, which allows the feet not to slip, which means there is no need to make unplanned stops. At the same time, the risk of injury on the road increases.

Experts tell us how to make a bicycle with a comfortable handlebar. It must meet the basic requirements:

ergonomics;
reliability;
strength.

The steering wheel is bent according to a pre-made sketch, but do not forget that it contains important control components that control the activation of the brakes, handles that change speeds, a sound signal, and a headlight. Modern bikes can be equipped with an on-board computer.

The steering wheel is fixed to the stem; it is preferable that the last component be adjustable. To assemble the steering wheel, use durable materials that will not let you down: steel, titanium or carbon.

Step-by-step instructions for making your own bicycle

Creating a Frame

Craftsmen tell us how to make a bicycle with your own hands, starting with the frame. It's unlikely that you can do the job yourself, so enlist the help of a friend. For the frame, prepare 7 pipes, 2 of them should be short, 4 medium ones - they are placed for the rear stays, the long ones remain for the underseat component.

Follow this frame assembly sequence:

Attach the lower main pipe to the carriage shell using a welding machine.
It should be fixed to the lower edge of the head tube located at the front of the bike. The position of the steering wheel is relative to the perpendicular of the carriage shell.
Following the parallel of the head tube to the glass, weld the seat tube with the down tube, taking into account the desired angle of inclination.
Then weld the seat tube and head tube to the main top tube. The front frame is ready.
Proceed to welding the chainstays to the carriage cup. The angle to the seat profile should match the angle of the main bottom.
Connect the top end of the seat profile to the edge of the chainstays to form the chainstays.

Pressing in the fork and making dropouts

The fork is pressed in in a horizontal position. How to make a bicycle yourself at the stage of pressing the fork, step by step instructions masters provide:

Mount the bearings.
Attach cones to the balls
Place the washer on the shock absorber rod.
Tighten the locknuts snugly, but do not overtighten the joint as this may cause the connection to break.

Take a metal plate and cut out some pieces.
Armed with a jigsaw, make indentations in the parts, the size of which should be suitable for the diameter of the wheel axle and fixing nuts.
The part is welded to the frame, applying it with the side without holes.

The landing recesses are placed at the same level, otherwise the wheel will not fit on the dropouts. The step between the mounting holes is equal to tightening the nuts to the maximum.

Installation of remaining components

A fully functioning great bicycle requires installation of working units on the frame. The most difficult thing is to install and debug the cranks and pedals on your carriage. And again, you can’t do without a guide on how to make a bicycle with your own hands:

Secure the steering wheel mounted into the shock absorber body with a bolt. The fork must be well lubricated before starting work.
Insert the seatpost vertically into the tube and secure it with a metal clamp and nut.
Place the carriage in the glass using a squeezer.
After installing the chain, install the wheels.

Conclusion

Now you have the knowledge of how to make a bicycle with your own hands almost from scratch. The work begins with the creation of a drawing, and after that the master’s idea is gradually brought to life. Some components can be made yourself, others are better purchased, so be prepared for the expense. The completed bicycle will become a real landmark of the area; everyone will probably want to ride such a device.