Scribd
Upload
512 views

Frame Jig Assembly Guide

The document provides step-by-step instructions for assembling a motorcycle frame jig. It lists the required tools and materials and details the construction of the left and right stands, height adjustment assemblies, and final frame assembly. The frame jig is constructed from steel tubing, plates, bolts, and includes adjustable height wheels for mobility.

Uploaded by

Malcolm Diamond
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
512 views

Frame Jig Assembly Guide

The document provides step-by-step instructions for assembling a motorcycle frame jig. It lists the required tools and materials and details the construction of the left and right stands, height adjustment assemblies, and final frame assembly. The frame jig is constructed from steel tubing, plates, bolts, and includes adjustable height wheels for mobility.

Uploaded by

Malcolm Diamond
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 12

Step By Step Motorcycle Frame Jig Assembly

Tutorial!

Motorcycle Frame Jig Assembly Guide:


Machinery and Tools Required:

1. Chop saw or Angle grinder.


2. Universal or CNC milling machine (recommended).
3. Plasma cutter (recommended).
4. MIG, TIG or Arc Welding.
5. Drill press.
6. Fitter’s vise.
7. Hammer, wrench set, tape measure, caliper.
8. Drill set.
Materials Required:

1. Mild steel square tube – 2’’ x 2’’ (235 ft).


2. Angle iron – 2 x 3’’ (156 in).
3. Mild steel sheet – 1/4’’ thickness (257 in2).
4. 1 ¼’’ tube (30 in); 1 ½’’ tube (62 in).
5. 3/8’’ threaded rod (32 in).
6. (4) HBOLT 5/8x45’’.
7. (16) HBOLT 1/4-20x3.25.
8. (14) HBOLT 3/8-16x3.5.
9. (4) 5/8’’ WASHER-NUT.
10. (4) 5/8’’ NUT.
11. (16) 1/4-20’’ NUT.
12. (14) 3/8-16’’ NUT.
13. (4) 5/8 WASHER.
14. (52) 3/8 WASHER.
15. (1) Retaining splint 1.
16. (1) Locking sleeve (Available from MCMASTER/GRAINER).
17. (10) Tube end cap (Available from various suppliers: 8020.net).
18. (4) Caster wheel CPS 40156TZ-ROI81(KK)TB.

1. Assembling The Left Stand.

Fig. 1.1 Left stand assembly welding plan.


Fig. 1.2 Left stand assembly montage
plan.

Parts:

1. Square tube 2 x 2 x 40’’.


2. Square tube 2 x 2 x 29.5’’.
3. Square tube 2 x 2 x 12’’ with 45º miter cut both ends.
4. Steering head plate 5 x 8 x ¼’’.
5. 3/8’’ Washer.
6. 3/8’’ x 3.5’’ Hex bolt.
7. 3/8’’ Nut.
8. Steering head shaft 1 ¼ x 30’’ .
9. Locking sleeve.
10. Retaining splint.
11. Square tube end cap.
12. 5/8’’ Washer.
13. 5/8’’ x 4.5’’ Bolt.
14. 5/8’’ Washer-nut.
15. 5/8’’ Nut.
16. 6 x 3/8’’ Set of washers.

Step 1: Cut two pieces of 2 x 2 x 29.5’’ and 2 x 2 x 40’’ long square tube using an angle grinder.
Take the 2 x 2 x 29.5’’ and drill 12 x 0.4 holes according to the drawing and then drill two 5/8’’
holes in 40’’ long piece. Take one piece of 29.5’’ and one piece of 40’’ long square tube and
position them on a flat work surface as shown on the next figure. Make sure the 90º angle is
accurate and complete the welds according to the welding plan (Fig. 1.1).

Step 2: Cut two pieces of 2 x 2 x 12’’ long square tube. Shape the ends at 45º using an angle
grinder. Position them as shown on the next figure and complete the welds according to the
welding plan (Fig. 1.1). Paint the frame in desired color.

Step 3: Cut two pieces 5 x 8’’ of ¼’’ thick mild steel sheet. Drill the holes and mill the slot
according to dimensions in the main drawing. Mount the steering head plate using the 3/8 x 3.5’’
bolts, nuts and washers as shown.
Step 4: Mount the steering head shaft using the 3/8 x 3.5’’ bolts, nuts and washers. During the
assembling use 6 x 3/8’’ set of washers as spacers (colored in green).

Step 5: Mount the locking sleeve to the steering head shaft threading the 0.075’’ X 1.75’’
retaining splint.
Step 6: Thread the 5/8 x 4.5’’ bolt, 5/8 washer and tight the 5/8 washer-nut. Screw the 5/8 nut,
but don’t tighten. Mount the square tube end caps.
2. Assembling The Right Stand.

Fig. 2.1 Right stand assembly welding plan.

Fig. 2.2 Right stand assembly montage plan.


Parts:

1. Square tube 2 x 2 x 40’’;


2. Square tube 2 x 2 x 29.5’’;
3. Square tube 2 x 2 x 12’’ with 45º miter cut both ends;
4. Rear axle mount plate 6 x 8 x ¼’’
5. Square tube end cap;
6. 5/8’’ Washer;
7. 5/8’’ x 4.5’’ Bolt;
8. 5/8’’ Washer-nut;
9. 5/8’’ Nut;
10. Small tube 1.2 OD x 2’’;
11. Threaded rod 3/8 x 16’’;
12. 3/8’’ Washer;
13. 3/8’’ x 3.5’’ Hex bolt;
14. 3/8’’ Nut;

Repeat Step 1 and Step 2 from chapter one.

Step 1: Cut two pieces 6 x 8’’ of ¼’’ thick mild steel sheet. Mill the slots according to
dimensions in the main drawing. Mount the rear axle mount plate using the 3/8 x 3.5’’ bolts, nuts
and washers.

Step 2: Take two small tubes, position them between the plates and align them to the slots
(colored in green). Put in the threaded rods through the slots and tubes. Thread the washers and
the others small tubes. Tight with 3/8 nuts.

Step 3: Thread the 5/8 x 4.5’’ bolt, 5/8 washer and tight the 5/8 washer-nut. Screw the 5/8 nut,
but don’t tighten. Mount the square tube end caps.
3. Frame Jig Height Adjustment Assembly.

Fig. 3.1 Height adjustment assembly montage plan.

Parts:

1. Caster wheel CPS 40156TZ-ROI81(KK)TB.


2. Height adjust plate.
3. Small tube 1.2 OD x 2’’.
4. 3/8’’ Washer.
5. 3/8’’ x 3.5’’ Hex bolt.
6. 3/8’’ Nut.

Step 1: Cut four pieces 4.5 x 4.5’’ of ¼’’ thick mild steel sheet. Drill the holes according to
dimensions in the main drawing.

Step 2: Take four small tubes, eight 3/8’’ washers and four 3/8 x 3.5’’ bolts. Arrange them
upside down as shown.

Step 3: Position the Caster wheel observing the montage plan (Fig. 3.1). Thread the 3/8’’
washers and tight the nuts.

Repeat the steps three more times, you will need four height adjustment assemblies.
4. How To Assemble The Motorcycle Frame Jig.

Fig. 4.1 Frame jig


montage plan.

Before start assembling the frame jig you have to produce part number 3 – Angle iron 2 x 3 x
78’’ long, and part number 9 – Square tube 2 x 2 x 24’’ long. See directions in chapter 1, Step 1.

Parts:

1. Left stand.
2. Right stand.
3. Angle iron 2 x 3 x 78’’ long.
4. 3/8’’ x 3.5’’ Hex bolt.
5. 3/8’’ Washer.
6. 3/8’’ Nut.
7. Height adjustment assembly.
8. 5/8’’ Nut.
9. Square tube 2 x 2 x 24’’ long.
10. 3/8’’ x 3.5’’ Hex bolt.
11. 3/8’’ Washer.
12. 3/8’’ Nut.
13. Square tube end cap.
Step 1: Align the holes of the left stand (1) and the front angle iron (3). Thread the bolts (4)
together with the washers (5) and then put in the rear angle iron (3). Screw the nuts (6) together
with washers (5), but don’t tighten them.

Step 2: Position the right stand (2) according to the montage plan (Fig. 4.1), between the angle
irons. Align the holes and repeat Step 1 directions. (NOTE: make sure that the used holes are on
the same level as the left stand, so the angle iron will be parallel to the ground). Align the left
and right stand to be parallel and tighten the nuts. Check alignment again, if there is some
discrepancy repeat the last step.

Step 3: Turn to one side the obtained frame, so you will be comfortable to mount the height
adjustment parts. Screw the height adjust plate (7) with the bolts as shown on Fig. 4.1. Mount the
rest three parts and turn the frame to normal position. Align the height turning the wheel
assembly and proceed to tighten the nuts (8).

Step 4: Mount the square tube beams (9) to the frame using the bolts (10), nuts (11) and washers
(12). Use 3/8’’ washers as spacers between the beams and angle iron (3), see montage plan.
Proceed to the last step, mounting the square tube end caps (13).

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy