The variety of mopeds on the market today is impressive. What designs you just will not find. But there will always be those who are not looking for easy ways and strive to make a moped on their own. Often, the main motives for such actions can be: lack of funds to purchase a moped, a desire to build a unique model, or simply a desire to try your hand.
Instructions
Step 1
Determine which parts of the future moped will be purchased and which will be homemade. With the exception of the engine in a block with a gearbox, the power supply and ignition system, the front fork, wheels, a gas tank and lighting equipment, everything can be done independently.
Step 2
First, sketch the future design on paper or cardboard. Then transfer it to a sheet of plywood and make a plaza - an exact life-size drawing. This will help to link all the elements of the moped and clarify its layout. Start snapping structural elements by placing the wheels.
Step 3
Determine the distance between them (base). Attach the front fork to the silhouette of the front wheel, and the steering wheel to it. Place the silhouette of the motor between the wheels in the most optimal place from the point of view of convenience and reliability of attachment to the frame. After that, combine all the nodes with a frame. At the same time, avoid unnecessary details, observe simplicity of forms and maximum manufacturability.
Step 4
Start with a frame. It must be welded from pipes of different diameters. Take material from unnecessary frames of other motorcycles and mopeds. They have the right stiffness, which cannot be said about water pipes. If you do not have welding equipment or skills, contact your workshop for help. Make the rear fork either from pipes or from steel strips. Cut out the engine mounting plates from sheet steel with a thickness of at least 3 mm.
Step 5
Before making the frame, prepare all its components. To bend the pipes cold, fill them with sifted dry sand, plug the holes with wooden plugs and bend using a simple pipe bender. It can be made from a car jack and a piece of rail. Attach the workpiece to the rail with a thick wire (at least 5 mm thick), bring the jack under the workpiece and bend the pipe, pushing the jack rod with the lever. Constantly control the work using a template - a piece of wire bent along the contour of the part shown on the plasma.
Step 6
Make the rear fork from a steel strip with a thickness of at least 5 mm. Make 10mm grooves in the fork stays for the rear wheel axle. Fasten the finished frame elements with soft wire and check the correct manufacturing and assembly. Tack gently by welding at 2-3 points at each joint, check again and weld completely. Install the engine mounting brackets on the frame, lightly gripping with welding. Check if the engine is properly attached to the brackets and weld it on.
Step 7
If necessary, attach a sprocket from any moped or a front sprocket from a bicycle to the rear wheel. Fasten with three M8 bolts with nuts. Place the wheels in the forks, secure the engine, power and ignition system, gas tank, saddle, headlight and lights, ignition coil, kickstarter, steering wheel and controls (throttle, clutch lever, manual or foot switch).
Step 8
Don't forget the brakes and footpegs. Install a simplified shoe-type brake on the rear wheel. It is quite enough for a light moped. Make the footrests from pipe sections and secure with welding. Add fuel to the gas tank, engine oil to the gearbox. Install the ignition in accordance with the instructions. After accelerating to 15 km / h, check the reliability of the brakes.
