DIY Network

Metalwork The metalwork begins and the chopper takes shape. From "Trade School" episode DTRS-204

Figure A

In this episode of DIY's Trade School, custom motorcycle apprentice Troy Westerman plays a vital role in creating a custom chopper for a statewide annual build-off competition (figure A). With shop owner Ruben Guerra and the veteran members of the shop guiding him, Troy learns quickly that in order to win this competition, the chopper must not only function--it must also look good.

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	Figure B
	Figure C

Basic Tools:

plasma cutter
shot bag
bossing mallets
English wheel
90-degree magnet
MIG welder
disc grinder

In this session Troy takes on the crucial job of fabricating one of the bikes signature features; the gas tank.

Before beginning any metalwork, the crew spends several days "mocking-up" the chopper to serve as a canvas for the work that follows. They start by installing a suspension, some engine components (figure B), and a rear tire (figure C). These components serve mainly for mock-up, as the final parts have not yet arrived at the shop. Once the chopper takes its basic form, the true craftsmanship can begin.

This bike's unique frame style dictates a unique custom gas tank as well. Most tanks sit on top of the frame's backbone, but this tank mounts underneath to feature the one-of-a-kind frame. Instead of a rounded tank, this tank has sharp angles created by adjoining several sections of shaped metal together.

To form the top section of the tank, Troy begins by tracing the space under the backbone onto a piece of cardboard (figure D). He then refines the shape of the trace and cuts the template out of cardboard. Troy traces it onto a section of 16-gauge sheet metal, and then flips it over and traces it again to create a mirror image of the pattern (figure E).

Figure D

Figure E

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