Wiktor Wise
Building an electric chopper motorcycle is a challenging yet rewarding endeavour. While it requires a range of tools and skills, from welding to electrical work, the process can be made more accessible by starting with a kit or bike in a box. This provides all the necessary parts, allowing builders to assemble and customise their chopper. Building from a kit offers a great learning experience, helping builders understand their strengths and weaknesses before attempting to build a chopper from scratch. For those seeking an even greater challenge, creating a chopper from a rolling chassis or a completely unique design is also possible, with parts available from motorcycle shops, junkyards, and online suppliers. Electric choppers, in particular, offer a clean, quiet, and low-maintenance riding experience, and builders like Ricky from Wannabe-Choppers have pioneered innovative designs in this space, challenging traditional motorcycle conventions.
| Characteristics | Values |
|---|---|
| Building from scratch | Requires a wide array of tools, from small hand tools to a welder, welding frame jig, and a lift table. |
| Building a kit bike | A less frustrating way to learn how to build a chopper, as all the parts are provided in a single delivery, and you only need to assemble the motorcycle. |
| Rolling chassis | A good alternative to a kit bike, as it provides the bones of the bike pre-assembled. Additional parts are required, along with electrical work and painting. |
| Electric chopper | A more sustainable and cost-effective option, with zero local pollution and a lower cost per mile than gasoline-powered motorcycles. |
| Electric chopper design | The electric motor and batteries can be hidden in custom saddlebags to resemble a delivery vehicle, or a mock aluminum engine can be used. |
| Parts | Parts can be sourced from motorcycle shops, junkyards, local dealers, after-market parts dealers, or online suppliers. |
| Learning | Building a chopper can help you understand your strengths and weaknesses and what you like or dislike in terms of parts. |
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What You'll Learn
- Sourcing parts: motorcycle kits, rolling chassis, or individual components
- Understanding the basics: how choppers and motorcycles are pieced together
- Tools and workspace: from small hand tools to welding equipment and a dedicated space
- Customisation: choosing a theme or modifying an existing motorcycle
- Registration and licensing: maintaining compliance with original manufacturer's registration
Sourcing parts: motorcycle kits, rolling chassis, or individual components
Building an electric chopper motorcycle can be a challenging but rewarding experience. Here are some options for sourcing parts and getting started:
Motorcycle Kits
One option for building an electric chopper motorcycle is to purchase a motorcycle kit, also known as a "bike in a box". This option provides all the necessary parts in a single delivery, and you just need to assemble the motorcycle. It offers a great learning experience, allowing you to understand your strengths and weaknesses and make adjustments to suit your preferences. While it is challenging, it is generally easier than building a motorcycle from scratch.
Rolling Chassis
Another alternative is to buy a rolling chassis, which is essentially the "bones" of the bike, pre-assembled. You will still need to handle the electrical work, source and fit the engine, and get the chassis painted. However, it provides a good base to work from and can be more affordable than purchasing all individual components separately.
Individual Components
If you want more flexibility and customization, you can source individual components yourself. This option usually suits advanced mechanics or experienced chopper builders who understand how different parts work together. You can look for parts in motorcycle shops or even junkyards, and it may be helpful to connect with communities and forums dedicated to chopper culture for advice and quality parts suppliers. Keep in mind that this option may require more time, effort, and space, as you will be building in stages and acquiring parts gradually.
Electric Components
When building an electric chopper, you will need to source electric vehicle components such as the motor, controller, power switch, and throttle. These can often be purchased from mail-order or web-based electric vehicle component suppliers. Additionally, consider the unique design challenges posed by electric choppers, such as incorporating a large battery in an aesthetically pleasing way.
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Understanding the basics: how choppers and motorcycles are pieced together
Building a chopper motorcycle from scratch is a challenging but rewarding experience. Before you begin, it's important to understand the basics of how choppers and motorcycles are pieced together.
Choppers are a type of custom motorcycle that emerged in California in the 1950s. They are characterised by their modified steering angles and lengthened forks, resulting in a stretched-out appearance. The name "chopper" comes from the process of cutting and welding the frame to reposition and restyle it, often with a longer front end and a stretch rake. This modification can make the motorcycle more challenging to handle and the ride bumpier due to the absence of rear suspension.
To build a chopper, you can start with a rolling chassis, which provides the basic structure, or "bones," of the bike. You will need a wide array of tools, including small hand tools, a welder, a welding frame jig, and a lift table. However, some home builders have used household items like a wood frame jig, saw horses, and cheap welders. You will also need to source the necessary parts, which can be purchased from a motorcycle shop or even a junkyard.
When piecing together a chopper, it's important to keep the original parts in case you want to revert to the original design or use them as backups. Additionally, you can sell the original parts to owners of the same make and model motorcycle. It's also crucial to understand the safety considerations, as many choppers lack basic safety features and can be dangerous to operate.
Building a motorcycle kit or a "bike in a box" can be a great way to learn the basics of how motorcycles are pieced together before attempting to build a chopper from scratch. With a motorcycle kit, you receive all the necessary parts in a single delivery and simply need to assemble the motorcycle. This allows you to gain experience and understand your strengths and weaknesses before tackling the more complex task of building a custom chopper.
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Tools and workspace: from small hand tools to welding equipment and a dedicated space
Building an electric chopper motorcycle from scratch requires a wide array of tools, from small hand tools to welding equipment, and a dedicated workspace. Here are the essential tools and workspace considerations for the job:
Small hand tools: Basic hand tools such as screwdrivers, wrenches, sockets, and pliers are essential for assembling and tightening various parts of the motorcycle. These tools will be used frequently throughout the building process.
Welding equipment: Welding is a critical step in fabricating the motorcycle frame and joining metal parts. A welding machine, such as a MIG or TIG welder, is necessary for this process. Additionally, a welding helmet, gloves, and other safety gear are crucial to protect yourself from the hazards of welding.
Frame jig and lift table: A frame jig is used to hold the motorcycle frame in place during assembly and welding. It ensures that the frame is aligned correctly and maintains its shape during construction. A lift table is also advantageous as it allows you to raise the motorcycle to a comfortable working height and easily access different parts during assembly.
Dedicated workspace: Building an electric chopper motorcycle requires a well-lit, uncluttered, and dedicated space. Ensure that the workspace is large enough to accommodate the motorcycle and all the necessary tools and equipment. It is important to keep the space organised and free from clutter to facilitate easy movement and access to parts during the building process.
While building an electric chopper motorcycle, it is important to consider your budget and the level of challenge you are willing to undertake. Purchasing a motorcycle kit or a rolling chassis can reduce the complexity of the project and provide you with pre-assembled parts, making the building process more manageable. However, building from scratch allows for greater customisation and a unique end product.
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Customisation: choosing a theme or modifying an existing motorcycle
Customisation is a key part of building an electric chopper motorcycle. You can either choose a theme and build the bike from scratch or modify an existing motorcycle.
If you're building from scratch, you can start with a motorcycle kit, which provides all the parts you need to assemble the motorcycle. This is a great way to learn about the process and understand your strengths and weaknesses. Alternatively, you can buy a rolling chassis, which is the 'bones' of the bike, and add the necessary parts, such as the electrical system, engine, and paint job.
When choosing a theme, you can start with one object, like a gas tank or carburetor, and build the rest of the motorcycle around it. This method requires a lot of time, resources, and advanced mechanical skills. You'll need to understand what parts work well together and where to source them.
Another option is to modify an existing motorcycle. This approach allows you to maintain registration and licensing more easily since you're working with an original manufacturer's vehicle. You can ride the motorcycle as is and then decide what modifications you want to make. Remember to keep the original parts in case you want to revert the changes or sell them to another owner of the same make and model.
Converting a traditional chopper bike into an electric one requires professional electric bicycle modification skills or seeking professional services. The process may include adding an electric drive system, installing batteries and controllers, and adapting the bike's structure. The cost of conversion depends on the electric system, accessories, and complexity of the modification.
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Registration and licensing: maintaining compliance with original manufacturer's registration
Building an electric chopper motorcycle can be a rewarding experience, but it's important to understand the registration and licensing requirements to stay compliant with the law. Here are some detailed guidelines on maintaining compliance with the original manufacturer's registration:
Understand the Basics of Registration and Licensing:
Before building your electric chopper motorcycle, familiarize yourself with the registration and licensing regulations in your state or country. These regulations can vary, so ensure you are aware of the specific rules that apply to your location.
Start with a Registered Motorcycle:
One of the easiest ways to maintain compliance is to start with an already-registered motorcycle and modify it to your liking. This way, you can retain the original manufacturer's registration and licensing. Ride the motorcycle first to understand what aspects you want to change and what you prefer to keep.
Obtain Necessary Documentation:
When building your electric chopper motorcycle, ensure you collect and maintain all the necessary documentation. This includes receipts for the purchase of major parts such as the frame, forks, motor, and seat. In some states, you may also need to obtain a Vehicle Identification Number (VIN) and apply for a title or a "builder's title" or "hobbyist license plate." Keep the original parts and their associated documentation as backup or for resale.
Comply with Power and Speed Limits:
To avoid additional registration and licensing requirements, ensure your electric chopper motorcycle complies with power and speed limits set by your state or country. In the US, for example, if your e-bike has a motor of 750 watts or less and a top speed of 20 mph, it may be exempt from certain registration requirements. Be mindful that exceeding these limits may result in the need for special registration and licensing, and even insurance requirements.
Registration and Inspection:
Once your electric chopper motorcycle is built, you will need to register it with the appropriate authorities. This typically involves submitting the necessary documentation and paying a registration fee, which can vary depending on your location. After registration, you may receive a sticker or a license plate that must be displayed visibly on your vehicle. Keep in mind that some states may also involve inspection, which can add to the overall cost and hassle of the process.
By following these guidelines and staying informed about the specific requirements in your location, you can ensure that your electric chopper motorcycle complies with the original manufacturer's registration and licensing regulations.
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Frequently asked questions
You can either build a chopper motorcycle from scratch, using a kit, or buy a rolling chassis. Building a chopper from a kit is a great way to learn how to assemble a chopper motorcycle, and you can also buy a rolling chassis, which is the bones of the bike pre-assembled.
Electric chopper motorcycles are clean, quiet, fun, easy to maintain, and reduce our dependency on oil. They are also cheaper to run, with the cost of electricity per mile about one-third that of a gasoline-powered motorcycle.
You can buy parts from motorcycle shops or junkyards, or order them online. Parts include the motor, controller, power switch, and throttle. You will also need a strong metal frame that fits under the driver's seat.
Building a chopper motorcycle from scratch will require a wide array of tools, including small hand tools and a welder. You can also take your frame to a local welding shop to be built for you.
