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Old 04-09-2009, 07:22 PM
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Default My Mini-Chopper Build!!!

Well I'm working on converting a chopper style bicycle into a 49cc 2 stroke Mini-Chopper, I have salvaged some parts from an older pocket bike (e.g. brake disc, mechanical calipers, 2 stroke motor and all the components from the handle bars). Here are some pics of my progress, all comments or questions are welcomed.
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Mini-Chopper 002.jpg   Mini-Chopper 003.jpg  

Mini-Chopper 004.jpg   Mini-Chopper 005.jpg  

Mini-Chopper 006.jpg   Mini-Chopper 001.jpg  

Mini-Chopper 008.jpg   Mini-Chopper 007.jpg  

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Old 04-09-2009, 10:27 PM
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Hey thats a sweet frame to start with. Looks like it will be a screamer. Are you going to run a belt drive or chain? Keep pics updated.
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Old 04-10-2009, 07:45 AM
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It will be chain driven
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Old 04-18-2009, 12:13 PM
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how are you going to attach the sprocket or pulley to the bike wheel? Or will you be using a different wheel? Also, how are you thinking of mounting the engine? Looks good.
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Old 04-18-2009, 06:40 PM
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I'm not sure about the sprocket yet, I have to get it and then I'll figure it out but I will be sure to feel everyone in and have pics. As for the motor this is how I am mounting it (pic below), of course it will look bigger in reality.
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Mini-Chopper 003-1.jpg  
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Old 04-18-2009, 07:39 PM
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This will be a cool build for sure.
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Old 04-18-2009, 07:42 PM
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I will definetly post pics along the way, was at the hardware store today and picked up a 6" x 16" 16ga plate to make the motor mount.
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Old 04-19-2009, 07:22 PM
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Well I worked on the motor mount today and got it welded in and then , I forgot about putting the carb back on when I test fitted it so now I have to cut a slot for the bowl of the carb to fit in But it still looks good, here are some pics. Comments and suggestions welcomed.
Attached Thumbnails
Mini-Chopper 4-19-09 005.jpg   Mini-Chopper 4-19-09 009.jpg  

Mini-Chopper 4-19-09 010.jpg   Mini-Chopper 4-19-09 003.jpg  

Mini-Chopper 4-19-09 004.jpg   Mini-Chopper 4-19-09 002.jpg  

Mini-Chopper 4-19-09 008.jpg  
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Old 04-19-2009, 08:13 PM
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Looking good!
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Old 04-19-2009, 08:14 PM
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How'd you make those holes... longwise? I never knew
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Old 04-19-2009, 08:18 PM
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Quote:
Originally Posted by oscaryu1 View Post
How'd you make those holes... longwise? I never knew
You drill two holes and cut the slot out with a jigsaw.
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Old 04-19-2009, 08:30 PM
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I layed it out and drilled two holes (one on each end of slot) and then cut the centers out with a grinder with a cut-off disc.
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Old 04-21-2009, 08:35 PM
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I got the slot cut for the carb and put the carb on to see what it looks like, here are a couple of pics.
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Mini-Chopper 4-21-09 001.jpg   Mini-Chopper 4-21-09 002.jpg  

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Old 04-22-2009, 09:07 PM
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that engine is exactly the same as what a kid in my metals class is using. he is making a scooter with it.
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Old 04-22-2009, 09:15 PM
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Oh yeah? Cool....It is a 47cc 2 stroke engine off a pocket bike.
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Old 04-22-2009, 09:18 PM
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If you're looking for performance, that stock carb doesn't do much.
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Old 04-23-2009, 12:02 AM
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Fix that pipe or buy one. The pocketbike engines need to have that expansion chamber for good tuning. You may also be able to run the pipe back under the engine instead of over it, as in the usual pb setup. I would suggest a heavy-duty clutch while you're at it.

The stock carburetor is probably one of the best carbs for the bike if set up correctly. New main jet, ported exhaust, better reeds, performance air cleaner with velocity stack ... the stock carburetor can even be race-ported for better air flow by drilling completely through the mouth of the carb with a 1/2" drill (you gotta be careful and go VERY straight, though, usually drill-press work).

If you need any help on tuning the engine, please shoot me a PM - I got four of the little things .....

Nice work on the build, please keep us updated.
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  #18  
Old 04-23-2009, 03:09 PM
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Hey spyguy do you know any good sites to by parts for the 47cc pocket bike engines?
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Old 04-23-2009, 07:06 PM
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Plenty:

www.davesmotors.com
www.scooterpartsdepot.com
www.scooterparts4less.com
www.partsforscooters.com
www.ebay.com

Dave's and SP4L.com are both really good on service and reliability - they ship out fastfastfast.
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  #20  
Old 04-23-2009, 08:16 PM
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be sure to gear your setup for torque ... these little motors have a hard time pushing pocket bikes at start and i think your frame is heavier than a pocket bike frame, also your wheels are bigger than pocket bike ones (like 12"?) so be sure to put the largest sprocket you could find on the rear wheel, othewise the motor will overheat trying to pull you and it will blow up... i know i blowed the head on mine... now it's fully rebuilt with quality parts and it's stronger than before!

just my 2 cents other than that the frame looks badass
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