Ducati Monster Forum

Well, I picked up this basket case suzuki intruder last week for around 1K.  My plan is to turn it into a bobber in the next 3 weeks, and ride it until I can sell it (and do it again).

Being that I'm a complete noob to machining, the going is slow.  I'm sure I could just go buy these parts, but this project is untra-low buck so I've got to use what I can find.

First up, making a strut:

Trim the huge post for the shock off, using the wrong blade on the sawzall = lots of fun  [laugh]

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0020.jpg)

Once I saw'd the post off, it was time to drill/tap it.  Well, I bought some used surplus (new?) boeing taps last week.  Too bad I had apparently tried to use the wrong drill bit (one size too small) and pop, broke the tap off.  Great.  That took about 2 hours to finally get out....pregnant dog.
(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0019.jpg)


Here is the sleeve, a bit too long now as I had to trim the post down.  No worries, it'll still work :)  Just need to trim it down.
(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0016.jpg)

Ouch.  Forgot to wear glove when grinding the bevel on the strut.  Strut slipped, grinder went into thumb.  Blood.
(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0015.jpg)

Welded on the bike
(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0014.jpg)


I've got to finish the upper sleeve (need a end mill or small boring bar) and weld it.  Other side strut is done, and I still need to drill tap the post.
(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/DSC_0013.jpg)


Not sure what to do about finishing the struts.  Frame is going to be flat black.  I figured I'd paint them, then chuck them back up in the lathe and touch the dimples I made to brighten them up.  Might rust then, I dunno.

All in all, took me about 4 hours to make the bits, still have one strut left to finish.  Should have another 2-3 hours in it to finish the rigid part of the tail.  Next up, lowering the front, shaving the front forks (rear drum only) and getting a seat/mounting it.

Thinking about one of those chopper pans, with some small shocks under it instead of the typical springs.  We'll see, thats $$$ (about 3 bills for the seat/shocks).  I'm trying to get in/out of this thing for $1500 total.

Ooooh, I like this.

What if you black out the struts, touch the dimples back to bare metal and then clear coat the whole thing? that should take care of your rust problem.  As for the seat issue, you might look into the small adjustable shocks they use on mountain bikes?  I've been toying with the idea of building a bobber and have thought about doing it that way, you can find them cheap CHEAP on ebay.  There's also a seller on eBay who sells pans relatively cheap

http://stores.shop.ebay.com/Accufast-2-d-Creating-Custom-Parts_Seat-Pans_W0QQ_fsubZ15842094QQ_sidZ11138673QQ_trksidZp4634Q2ec0Q2em322 (http://stores.shop.ebay.com/Accufast-2-d-Creating-Custom-Parts_Seat-Pans_W0QQ_fsubZ15842094QQ_sidZ11138673QQ_trksidZp4634Q2ec0Q2em322)

keep us updated please ;D

What if you hit a pothole?  Rather unsafe looking...

Whats this safety thing you speak of ? [laugh]

Thanks for the link Ducatl, looks promising.  And the exhaust box you've built  [clap] [clap]

Cool project. Can't wait!!! Celli

Thanks Celli!

Update:

I started doing lots of other stuff, cleaning the spokes/wheels, ordering some metal, etc.

Today I started to make a set of bars......I apparently bought 4' of 1" not 5', so I was only able to finish up half a set of bars.  They didn't turn out to bad for my first attempt, although I may cut them apart and make some adjustments.  Worlds better in feel and looks than the stockers though.

I also need to buy some new risers, as the stock ones are half busted (bolts broke off flush) and the rubber mounting sucks (although I should be able to fix that somehow.

Anyway, I also finished up the struts, cut the rear fender, and got some new tires.  Tomorrow I'll mount the tires, and then I should be able to finalize the rear fender mounting/placement.  Also, I should have my seat pan in then and can get started figuring out that piece of the puzzle.

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/barsstarted.jpg)

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/welding.jpg)

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/Frontview.jpg)

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/barsback.jpg)

As suggested above, I'll be keeping the front brake and the foot clutch as well.   I've got a much more appropriatly sized bike in mind for my next build (I'm 6'5" and make this one look pretty small).   I'd like to do a Vtwin based bike with a 250-280 rear tire and lots of room to stretch out.  Jockey shift and foot clutch = MUST on that one (I'll keep it forever).

Just some updates:

Finished bars, shaped seat pan, made seat hinge, made seat spring mounting plate/box (that looks like johnny 5's head)

Basic "look" is there.

(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/johny5.jpg)


(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/photo.jpg)



(http://i3.photobucket.com/albums/y54/TheoAftonomos/Intruder%20chopper/seatmount.jpg)

Yes!