HEAVY METAL: The Re-Cycle

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Recently, I decided to put my welding skills to the test (I've actually been on this project a couple of weeks) and build myself a pocketbike. The catch is, it's not just any pocketbike. This is all custom-built from scrap metal I had just laying around, plus parts from several junker bikes and gopeds.So it begins ..... the Re-Cycle.http://i404.photobucket.com/albums/p...ttankengin.jpgHeight: 20" at handlebars, 15" at seatLength: 28"Width: 8"Wheels: 4" goped wheelsDrivetrain: 47cc pocketbike engine with CVTRequired:-Needs to be short enough to fit under the tonneau cover of my truck so it can be fully closed and locked - max 16".-Front end easily removable to accomplish this, perhaps removeable handlebars.-Use pocketbike engine and goped wheels for drivetrain - #25 chain.-EXTRA CHALLENGE: make it all from recycled metal laying around. Only purchased items can be drivetrain and wheels.http://i404.photobucket.com/albums/p...ebeginning.jpghttp://i404.photobucket.com/albums/p...rorsolater.jpghttp://i404.photobucket.com/albums/p...rorsolater.jpgThe frame is made of four tire irons welded together, the inside of the wrench ends filled with - what else? - car lugnuts. The engine plate used to be part of an office keyboard track, with a curved slot cut out for carburetor clearance, and the crossmembers on the frame were bicycle kickstands.The head tube is a small section of pipe with car lugnuts on either end, and a large 1/4" gusset plate to tie it into the arms of the frame.http://i404.photobucket.com/albums/p...topofframe.jpghttp://i404.photobucket.com/albums/p...setinplace.jpghttp://i404.photobucket.com/albums/p...Welding%20And%http://i404.photobucket.com/albums/p...arwheelmoc.jpgComparison - that's a full-size Cag/Daytona frame the bike is sitting next to: http://i404.photobucket.com/albums/p...sizedCagfr.jpghttp://i404.photobucket.com/albums/p...sizedCagfr.jpg(** Note: Earlier photos show a different head tube, made from a small section of 3/8" water pipe inside two sleeves, attached to one arm of a 3-piece bicycle crank. This design didn't work out very well, as the pipes wouldn't take a good weld and hold together. After several hours of frustration and easily-broken welds - not to mention enough cussing to make a sailor blush  - out came the cutting wheel. **)http://i404.photobucket.com/albums/p...themistake.jpghttp://i404.photobucket.com/albums/p...hthispiece.jpghttp://i404.photobucket.com/albums/p...orheadtube.jpghttp://i404.photobucket.com/albums/p...setinplace.jpghttp://i404.photobucket.com/albums/p...ubeinplace.jpgThe rear wheel mounts are cut-down training wheel mounts. A funny thing about goped wheels - the axles are fastened INSIDE the wheels, and can't be slid out like regular pb wheels (or if they have, I haven't found out how yet.) To accomodate this, slots were cut in the axle mounts with a 4" angle grinder and cutting wheel.http://i404.photobucket.com/albums/p...kets-aintm.jpghttp://i404.photobucket.com/albums/p...elbrackets.jpghttp://i404.photobucket.com/albums/p...ngwheelset.jpgThe front forks are also tire irons, with 1/4" steel plate for triple trees, and chopped-down training wheel mounts, doing the same trick with the slot. (Been using a LOT of cutting wheels - that 1/4" plate is tough stuff!)http://i404.photobucket.com/albums/p...ngtheforks.jpghttp://i404.photobucket.com/albums/p...elystraigh.jpghttp://i404.photobucket.com/albums/p...wheelmount.jpghttp://i404.photobucket.com/albums/p...ngtheforks.jpghttp://i404.photobucket.com/albums/p...eadjusting.jpghttp://i404.photobucket.com/albums/p...ingonforks.jpg(Yah, I know, the front forks aren't gonna turn with that big plate like that. I just didn't get a picture of the bottom end cut out yet.)Hey, starting to look like a bike now! http://i404.photobucket.com/albums/p...slikeabike.jpghttp://i404.photobucket.com/albums/p...slikeabike.jpghttp://i404.photobucket.com/albums/p...eelsmockup.jpgWell, let's drag out one of the Cags, and see what we've got here .....http://i404.photobucket.com/albums/p...l-sizedCag.jpghttp://i404.photobucket.com/albums/p...l-sizedCag.jpghttp://i404.photobucket.com/albums/p...l-sizedCag.jpgYup, those are tire irons in the picture, too - exactly what I used to build this little beast.Gas tank is a stock Cag/Daytona tank, secured with a big ol' hose clamp in pure redneck style. Yup, that IS a bicycle seat! The pipe it's mounted on used to be a set of mountain bike handlebars, cut and notched to fit on the new frame, and supported by a really big nut.http://i404.photobucket.com/albums/p...tankmockup.jpghttp://i404.photobucket.com/albums/p...ttankengin.jpghttp://i404.photobucket.com/albums/p...ttankengin.jpgKinda hard to believe those are the same size wheels, huh?http://i404.photobucket.com/albums/p...ethosearet.jpgJust to give y'all some reference points on this bike to show how REALLY small it is ...-From the ground to the top of the head frame is between 12"-13".  In comparison, a standard vehicle license plate is 12" from side to side.-Each of those wheels stands 9" tall, from ground to top of tire.  A standard stock Cag/Daytona tire/wheel combo is over 11".-The top of the gas cap on the yellow bike (btw, that's a Cag) sits at 22" from the ground.  My handlebars are 2" shorter.Future plans for the bike include brake and throttle levers, upper engine mount, brake bracket mount, shorty exhaust pipe with goped can, footpegs, and kickstand. Gusset plates for additional frame strength are also in the making.To be continued .....
Reply:none of the picture links are working they look incomplete
Reply:Links don't work.  Choose the "image" icon under the pictures to embed them here.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Not to complain, but this forum is called Welding Projects and Pictures.It's not called Links to other sites. Thank you, come again.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Oops, sorry guys, I blew it on the links ...... Let's try this again, without all the commentary ....Height: 20" at handlebars, 15" at seatLength: 28"Width: 8"Wheels: 4" goped wheelsDrivetrain: 47cc pocketbike engine with CVTThe beginning:http://i404.photobucket.com/albums/p...ebeginning.jpghttp://i404.photobucket.com/albums/p...rorsolater.jpghttp://i404.photobucket.com/albums/p...rorsolater.jpgBuilding the top and bottom of frame:http://i404.photobucket.com/albums/p...topofframe.jpghttp://i404.photobucket.com/albums/p...setinplace.jpghttp://i404.photobucket.com/albums/p...arwheelmoc.jpghttp://i404.photobucket.com/albums/p...arwheelmoc.jpgComparison beside full-sized Cag/Daytona pb frame:http://i404.photobucket.com/albums/p...sizedCagfr.jpghttp://i404.photobucket.com/albums/p...sizedCagfr.jpgThe mistake, and the repair:http://i404.photobucket.com/albums/p...themistake.jpghttp://i404.photobucket.com/albums/p...hthispiece.jpghttp://i404.photobucket.com/albums/p...orheadtube.jpghttp://i404.photobucket.com/albums/p...setinplace.jpghttp://i404.photobucket.com/albums/p...ubeinplace.jpgRear wheel mounts:http://i404.photobucket.com/albums/p...kets-aintm.jpghttp://i404.photobucket.com/albums/p...elbrackets.jpghttp://i404.photobucket.com/albums/p...ngwheelset.jpgFront forks and front wheel mounts:http://i404.photobucket.com/albums/p...ngtheforks.jpghttp://i404.photobucket.com/albums/p...elystraigh.jpghttp://i404.photobucket.com/albums/p...wheelmount.jpghttp://i404.photobucket.com/albums/p...ngtheforks.jpghttp://i404.photobucket.com/albums/p...eadjusting.jpghttp://i404.photobucket.com/albums/p...ingonforks.jpgHey, looks like a bike! :thumbsup:http://i404.photobucket.com/albums/p...slikeabike.jpghttp://i404.photobucket.com/albums/p...slikeabike.jpghttp://i404.photobucket.com/albums/p...eelsmockup.jpgComparison to full-sized Cag/Daytona pb: http://i404.photobucket.com/albums/p...l-sizedCag.jpghttp://i404.photobucket.com/albums/p...l-sizedCag.jpghttp://i404.photobucket.com/albums/p...l-sizedCag.jpgGas tank and seat mockup:http://i404.photobucket.com/albums/p...tankmockup.jpghttp://i404.photobucket.com/albums/p...ttankengin.jpgThe same wheels as that goped!http://i404.photobucket.com/albums/p...ethosearet.jpg
Reply:OoopsROFLMAO"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Oops, I take my oops backI thought it was 'nother string of non working links"Any day above ground is a good day"http://www.farmersamm.com/
Reply:No, this time I checked more carefully before I posted 'em ...
Reply:Did a few more things to the bike today, wanted to share .... Reference photo - a standard-sized license plate is 12" long:http://i404.photobucket.com/albums/p...comparison.jpgNow, standing on end next to the bike:http://i404.photobucket.com/albums/p...comparison.jpgDifference in wheel sizes:http://i404.photobucket.com/albums/p...Wheelsizes.jpgHead to head on my truck bed:http://i404.photobucket.com/albums/p...Headtohead.jpgTail to tail.  The top of my rear frame is about level with the top of the pb's rear tire, maybe a shade lower.http://i404.photobucket.com/albums/p...Tailtotail.jpg----------------------------------------------------------------Did some work on the bike today, not much, just some cutting, grinding, and a little welding.  A shot of the front forks - I needed to make the rear of the plates more triangular so I could turn the bike easily:http://i404.photobucket.com/albums/p...mmingedges.jpgAnd a shot from the front:http://i404.photobucket.com/albums/p...orfrontwhe.jpgMade a minor miscalculation on the height of the lower triple tree, had it too low and it was scraping the tire.  Five minutes and several cuts later, problem solved.http://i404.photobucket.com/albums/p...frontwheel.jpgMounted up the footpegs today - can anyone guess what they are?http://i404.photobucket.com/albums/p...egsinplace.jpghttp://i404.photobucket.com/albums/p...egsinplace.jpgIf you guessed the handles from a fireplace set, you're right!  Those rings were originally the top parts of the handles.  I found a couple of bolts that threaded into the handles, then welded the bolts to the frame and screwed the handles on, along with a couple of jam nuts to keep the pegs properly set.  They DO stick out a little far - look Ma, no kickstand needed! - but can still be unscrewed for storage.http://i404.photobucket.com/albums/p.../54-Mockup.jpghttp://i404.photobucket.com/albums/p.../55-Mockup.jpg
Reply:I gotta tell ya dude:  I love it!  'specially the use of the tire irons...whoda thunk it?(Retired) Professional firefighter, amateur everything else I try to do...Oh yeah:  Go Big Red!   (You know: one of the 12 members of the Big 10 cuz we left the 10 members of the Big 12...)
Reply:Well, it's not like I didn't have them available .... Actually, the tricky part about using the tire irons was finding two bars that were EXACTLY the same.  I had to lay out all of them on the ground, then measure each one against another to see if they matched up correctly.  I wound up with about five matched pairs and a buncha oddball ones.  The two on the forks were the longest I had, although I probably could've gone to the next size down .....Hit my first major snag on the bike - well, not major, but annoying. The gear on the CVT transmission doesn't quite match up with the pocketbike sprocket on the rear wheel, looks like a different pitch on the teeth altogether. I DO have the matching gear for the CVT for the rear sprocket, but no chain!  (After some research, looks like the CVT gear is originally for a dirt minibike, which is 8mm chain - pocketbikes use a thinner #25 chain.)  *sigh*  Ordered a new CVT #25 gear this morning, should be here in a couple of days .... Well, the downtime will give me time to grind down, clean up, and recheck any welds I've done so far.Last edited by SpyGuy; 10-13-2009 at 01:37 PM.
Reply:Hey, if it was easy, everyone would be doing it!  That's what makes yours so cool!(Retired) Professional firefighter, amateur everything else I try to do...Oh yeah:  Go Big Red!   (You know: one of the 12 members of the Big 10 cuz we left the 10 members of the Big 12...)
Reply:Take that, you sweet thing!Find a telemarketing service company | Telemarketing company for b2b and lead generation | Outbound telemarketing lists
Reply:Meanwhile, all welds are fairly cleaned up and ground down, throttle and brake levers are loosely mounted.  Sorry, no pics on those, didn't have my camera with me.Still need to fab up a brake bracket mount and an upper engine mount, looking at using old wrenches for the top mount.  One of my fixer-upper bikes is donating the engine for now, so hopefully as soon as I get the gears, I can finally get this little thing rolling.
Reply:Been a little while since I've posted, so I thought I'd bring y'all up to date on the Re-Cycle:Since the last time I posted, I've done several other things to the bike.  I needed to fit a brake bracket on the rear so I would have some way of stopping this little beast.  The bracket on the axle was stock, so I fabbed up a tab on the frame to bolt up the crossbar:http://i404.photobucket.com/albums/p...brakesetup.jpgNow, I needed an exhaust pipe.  A regular pocketbike pipe wouldn't fit, as those run over the top of the engine, and the mototrized bicycle pipe I had hung way too low, and would be more of a stand to pick up the rear of the frame.  The goped can exhaust I had would work, BUT ... the bolt holes were just slightly off, maybe about 1/4"-1/2" from the ones in the cylinder.  great .......... now I have to fab one.  Using an old trashed pb exhaust pipe, I sliced off the header end, then welded a large washer to the stubby pipe.  Nuts were added on either side to attach the goped can exhaust.My shorty exhaust:http://i404.photobucket.com/albums/p...ndgopedcan.jpghttp://i404.photobucket.com/albums/p...ndgopedcan.jpgAnd on the bike:http://i404.photobucket.com/albums/p...pipeonbike.jpghttp://i404.photobucket.com/albums/p...pipeonbike.jpgAdmittedly, the exhaust pipe hangs a little lower than I'd like, so another even shorter header pipe will be fabbed up.Now, the chain: First off, I didn't have the correct gearing - turns out when I ordered the CVT, it had a gear with a slightly larger pitch than a normal pb chain (needed a #25 chain, actual order shipped turned out to be something like 8mm).  Once I got my new gear shipped, everything went together just fine.  (Okay, I lied .... I didn't really pay too much attention to how the old gear went on when I installed the new one.  As I went to cut the chain, I suddenly realized that the gear were way off!  OMG - what did I do??  Did I screw up on the measurements?  I had it all measured and lined up straight!  WTF????  After all that work I did, measuring and marking and drilling, now I gotta do it all over again! ... Oh .... installed the CVT gear backwards .. duh ...)http://i404.photobucket.com/albums/p...hainfitted.jpgSo here it is as it sits right now.  Throttle and brake levers mounted and hooked up, good running engine installed, tank clamped down and lines plumbed, stubby exhaust pipe bolted up.  I did goof on the chain - cut it one link too short, but that's a fairly easy fix.http://i404.photobucket.com/albums/p...hainfitted.jpghttp://i404.photobucket.com/albums/p...hainfitted.jpgStill need to do a few minor things to it, such as fabbing up an upper engine mount and some work on the brakes, but for now, the hardest part of the build is done.  Brake and throttle levers need some tweaking, might have to put spacers underneath the handle so they won't flop around.  I'm also thinking of adding a front brake, and running both brakes off the same lever.
Reply:It's alive ... ALIVE ........ ALIVE !!!!!!!!Well, today was the day.  Poured some gas in the tank, flipped the choke lever up, turned on the gas, gave it four quick pulls, and VROOM!  Loose brakes, no killswitch (well, okay, I had a bare wire), wobbled some, carb leaked (don't they all?), but damn, it runs!  Woohoo!  Took it for a quick spin around my driveway, running circles around the drieway in front of my two-car garage, then took it for a quick run back and forth in front of the house.  The CVT provides a surprising amount of torque, and I was able to get up to a decent 10mph with lots of throttle to go (didn't want to go any faster because of the brake issue ....)  Not like it's going to run much faster than that, since I mainly made it for a fairgrounds / swap meet cruiser ....As usual, there are the normal little things here and there that need tweaking and tuning, but for the most part, The Re-Cycle is complete and running.
Reply:Well, The Re-Cycle made its first public appearance today.  We were holding a mini track meet at a local motorcycle shop that allows us to use its rear parking lot.  EVERYBODY thought the bike was really cool, and couldn't believe that it was al made from tire irons and scrap metal!  After a leaky carburetor was changed out and the idle adjusted, the bike fired every time after three hard pulls.  It wound up being used as a mini-pitbike to run from one end of the track to the other, and performed flawlessly each and every time.  That CVT makes the bike pull like a freight train, and just keeps on pulling during acceleration.  I have to say I'm VERY happy with its performance, and glad i took the time to take on this challenge.  I still need to work out a bug or two, like a proper killswitch, maybe grind a couple of welds down smoother, but it runs!!!One of the guys on another forum is trying to talk me into putting a mini-sidecar on it.  Maybe, but that may be a project for the next Re-Cycle .... This one still needs to be stripped back down and painted, most likely FFB (Flat Effin' Black) primer, the only color to put on something like this ...
Reply:Been a long while since I've posted anything on this thread, so I wanted to show off a couple more pictures of the completed bike.All complete with new flat black paint job and red front rim:(Since this picture was taken, I've also added a saddlebag on the left side made from an old Army .30-caliber ammo can.)Mounted a set of receiver tubes underneath the engine for the sidecar (when I get around to building it, having too much fun riding it as is!):Dig that crazy upper engine mount.  That's a pair of 1/4" wrenches, with the head of a 9/16" wrench in between to hold them apart:Busted another 1/4" wrench in half, so that became my tank mounts.  Why is the killswitch underneath the seat?  Because that's the only "normal-sized" pipe onthe entire bike!And then just something else I put on for fun:
Reply:Very nice.
Reply:curiuos....how'd you end up with so many lug wrenches?  lol.
Reply:BurningMetal: The same way I wind up with all the other little odd bits and pieces I use for my metalwork - I raid thrift and junk stores.and garage sales.  All of the wrenches on this bike (lug wrenches or otherwise) were found at various stores and garage sales, and I have a few people who actually call me to let me know that "Hey, I got some old junk metal stuff you may be interested in ...."My main goal was to use as much recycled metal as I could - most of the cost of the build was for the CVT and the wrecked goped I picked up for the wheels and controls.  I already had the engine (normally $120.00) and the gas tank (I actually DID replace the old tank with a new one, $12.00, although the old one was still serviceable),  The CVT was $50.00 at the time I got it.  The tire irons were a buck apiece, so were most of the other wrenches. The goped was $40.00, and donated the wheels, seat, controls, and brake set.  Oh, and the horn was bought brand-new at an outrageous price of $8.00!!   All told, I've spent maybe $150 on the bike, including paint.  (Okay, I DID switch out the rear rim from my Kragen Zooma for the broken one, and recently replaced that rim with a new assembly, but that doesn't count.)The kick I get from seeing the looks on people's faces when they figure out the bike is all hand-built?  Absolutely priceless ....
Reply:Great project.  The tire irons are great.Common sense in an uncommon degree is what the world calls wisdom.
Reply:It was definitely a challenge to build, bu tthe end results are totally worth it.  The guys are getting a big kick out of seeing it every time I bring it out to practice.
Reply:Pretty cool. I saw this bike at a bikefest in 2007. Similar idea, but a lot more $$! Attached ImagesMiller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:This little motor is a good invention. I think my kids can ride a this bike without license.