Introduction: Assembling the 8020 Chopper

Picture of Assembling the 8020 Chopper

Step by step assembly guide.

Step 1: The Headset

Picture of The Headset

Step 2: Attach Forks

Picture of Attach Forks

You wan to make sure that there is sufficient pressure on the bearing cups, otherwise there will be play in the headset.

Step 3: Front Dropouts and Brake

Picture of Front Dropouts and Brake

Front dropouts - fairly obvious, but need to be well aligned for wheel to sit straight.

Step 4: Handlebars

Picture of Handlebars

Step 5: Attach Top and Downtubes

Picture of Attach Top and Downtubes

When attaching brackets, its a good idea to loosely tighten them because chances are they will need to be adjusted later.

Step 6: Seat Tube and Bottom Bracket

Picture of Seat Tube and Bottom Bracket

Step 7: Attach Top Tube to Seat Tube

Picture of Attach Top Tube to Seat Tube

Step 8: Rear Rails and Dropouts

Picture of Rear Rails and Dropouts

Remember to put the chain inside the rear triangle before attaching the dropout.

Step 9: Mount the Rear Wheel

Picture of Mount the Rear Wheel

This is where you are going to make all of your geometry adjustments and tighten every thing down.

Step 10: Mount the Seat Braces

Picture of Mount the Seat Braces


Odziz (author)2009-06-21

What grade of 80/20 was used in this project ? 10, 15, 30 etc.

Visitor (author)2007-04-04

Great photos, but you really do need to add more text. A picture does not really help anyone identify the possible problems in the process.

downhilldman (author)Visitor2008-10-25

I agree, you don't really explain too much what you are doing

GibbonsRock (author)2008-08-29

Hey dude! The bike is all kinds of awesome (+5!) , but I'd really really really like to know more about the 80/20 based CNC table in the back- it looks to me like it's a convertible plasma torch and wood router. I'm currently building an 80/20 based CNC machine. Cheers, Jim

AnarchistAsian (author)2008-08-07

he he he, check this out

AnarchistAsian (author)2008-08-06

where did he get the seat, handlebars, and pedals from?????????????????????????????????????????????????

AnarchistAsian (author)2008-08-06

this=cool=i give it a 5!!!

limpach (author)2008-08-06

Its Beautiful!

ewilhelm (author)2008-08-05

Alert! This bike, one of the very first Instructables projects, was stolen from Alameda, CA near Webster and Atlantic. If you see anyone riding it, take pictures and report it! There's even a reward!: 24' length of 8020!!!

Thornburg (author)ewilhelm2008-08-05

That is really sad to hear knowing how much time and effort he put into that.

Sandisk1duo (author)ewilhelm2008-08-05

sorry about that : (

Dorkfish92 (author)2007-04-09

What are the metal bars called that the bike is made from?

BinaryCortex (author)Dorkfish922007-06-11

I was wondering the same thing, so I searched on 8020 as it says in the title and found this site.

sovereign (author)BinaryCortex2008-08-05

its an aluminum extrusion used in industry to build nearly anything. It's relatively inexpensive, and can be found discounted online.

watermelon (author)2007-04-19

What a great idea for a bike you want to take with you on the bus, train or plane with just a few less parts!

HamO (author)2007-04-05

Well done, great looking bike. Nice pix!

trebuchet03 (author)2007-04-03

Was this from that bike design class you guys had awhile back?

About This Instructable




More by saul:Bamboo Chalk changing egg tricktraining wheels for your helicopter.
Add instructable to: