Assembling the 8020 Chopper

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Introduction: Assembling the 8020 Chopper

Step by step assembly guide.

Step 1: The Headset


Step 2: 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

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

Step 4: Handlebars


Step 5: 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


Step 7: Attach Top Tube to Seat Tube


Step 8: Rear Rails and Dropouts

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

Step 9: 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


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    18 Discussions

    great project, I would have run the brake cable through the hole in the center of the 80/20

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

    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.

    1 reply

    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

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

    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!!!

    2 replies

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

    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!

    Well done, great looking bike. Nice pix!