Crazyhorse's How to stretch a StingRay Chopper conversion into a XXL Chopper!

[Crazy Horse]

This is how I Stretch / Convert most styles of StingRay Choppers or Clone OCC Chopper into a Schwinn XL Chopper or the Schwinn XXL Chopper style build.

Here's a Parts & Tools list that you'll need to get started:

Tools and Equipment:

For cutting the frame up use a hack saw, reciprocating saw ( Sawzall ), angle grinder, or steel chopsaw for the straightest cut.

For welding the frame back together, a welding shop or your own personal welder.

I use 1-3/4" round steel tubing for the top tube, and downtube from headtube.

I'd suggest sleeving slightly smaller steel tubing inside the 1-3/4" steel tubing for extra strength for the new extended steel tubing that you'll be using on the top tube which runs from the headtube to the rear triangle and the for the new extended tubing which you'll be using on the steel tube which runs from the headtube to the bottom bracket also known to some builders as the pedalcrank.

I use 1-1/2" X 4" X 16-gauge rectangular steel tubing for the bottom tube.

You can build this Stretched Chopper as an XL Chopper with a 22" bottom tube, or you can build this Stretched Chopper as an XXL Chopper with a 30" bottom tube.

Notice: Remember your leg length should determine the amount of Stretch you decide on, 5-7-inches to 6-feet tall you'd want to only add a 22-inch bottom tube. 6-feet or taller go for the XXL Stretch Chopper with bottom tube measurement of 30-inches.

You also need 2 stock 20-inch StingRay or OCC Style Chopper Bicycles to chop for your build. Or just one if you can source the 1-3/4" round steel tubing.

I prefer using the 1-1/2" X 4" X 16-Gauge Rectangular Steel Tubing for the bottom tube so that I can easily add a Honda crf50 or Pitbike, and or kids ATV ( 49cc - 125cc ), engine's to the square / Rectangular bottom tube.

I'll be posting a few how to pictures showing you where I cut my frames, and other pictures as I go through the build.

Here's what a stock / regular sized 20-inch StingRay Chopper frame with a 14.50-inch bottom tube looks like next to a XXL Chopper with bottom tube measurement of 30-inches . Notice the Xl Chopper Bicycles have a bottom tube measurement of 22.50-inches.





Here's what the Round Steel Tubing and Rectangular Steel Tubing I use looks like.



This what you'll be aiming for if you go for the 30-inch stretch for a XXL Chopper.



To be continued soon....I have to upload pictures of where I cut the frame, then I can post them.

[Crazy Horse]

A few more pic's of where I make cut's to Stretch the frame on the Schwinn StingRay Chopper.

I put a coat of grey primer on the frame, so that I could write with black magic marker showing the cuts to make.

On the Top tube I measure from the rear triangle 11-3/4" this measurement keeps the front gusseted portion of the frame intact.

On the tube from headtube to bottom bracket I measure up from the bottom bracket 6". After this cut the front of front section of frame is now removed.

The final cuts I make are complete removal of the oval shaped steel bottom tube. I start by cutting around the seat downtube, trying to save as much of the seat downtube as possible.

Then I cut the bottom tube just in front of the rear triangle, then I cut the remaining portion of the bottom tube off the bottom bracket.

You are now ready to start mocking up the frame and measuring your new steel tubes to be used for lengthening your frame.

Pic's

Here's the primed frame with measurements / marks showing where I make my cuts.

[buba]

go to it crazy

thanks for posting

i have a accumulated a few of the little choppers and strong bmx's with some vague ideas of chop --strretch and end up-0 with something strong and worthwhile engine choices are you going with the lifan's you favor???? or ????

you inspire and motivate

thanks buba

[Crazy Horse]

Originally Posted by buba

go to it crazy

thanks for posting

i have a accumulated a few of the little choppers and strong bmx's with some vague ideas of chop --strretch and end up-0 with something strong and worthwhile engine choices are you going with the lifan's you favor???? or ????

you inspire and motivate

thanks buba

Thanks buba, and yes this build will most likely be motorized with a Honda Mini Trail 50 ( 49cc ) chinese cloned engine.

Although the Harbor Freight Tools,
HORIZONTAL ENGINE, GASOLINE, 212CC OHV 7HP PREDATOR ENGINE- Item#69730 this alternative engine will easily fit the Stretched Schwinn StingRay XXL Chopper it's a thought haven't decided which engine I'll use yet.

Here's what I've accomplished today.

I start with notching the rectangular steel tubing which I use for the new bottom tube. I notch it so that 1/2" of the rectangular steel tubing it slides under the rear triangle doing this adds strength to the rear triangle. See pic's.











Next I'll notch the rectangular steel bottom tube and weld the bottom bracket. Then I'll add new extended 1-3/4" round steel tubing for top tube and new down tube.

[LabRat]

Will you put pedals back on the frame or will you use an engine with the pedals?

[Crazy Horse]

Originally Posted by LabRat

Will you put pedals back on the frame or will you use an engine with the pedals?

Gotta have them pedals here in the Washington, D.C. area to get the Moped designation / Registration.

Or use this Honda crf50 style pitbike engine used on the SSR Laser / Motorino Pedal moped engine, with the built in pedals on the engine.

See pic's below:







Working on my tubing notcher right now Labrat, trying to get a good fishmouth cut to weld up the bottom bracket to the rectangular steel tubing just right.

I'll post up some pic's soon.

C.H.

[Crazy Horse]

Well, I thought I'd share some updated pictures of this slow but ongoing build.

The bicycle frame Jig is a Culvercityclassics and Sportscarpat inspired home shop version.

1.
Using Culvercityclassics bicycle frame jig version of C-Channel also known as Uni-Strut, with spring nuts and angles etc...

2.
Using Sportscarpats version of an engine stand so I can rotisserie ( rotate the frame ) spin the frame so I don't stress my back into a position not unlike the old 1970's game called twister.

Thanks to both of you, you are both gentlemen and artist's.





See more info parts & pictures here in my Bicycle Frame Jig Album on how to build your own personalized version of this bicycle frame jig.

Just click on link below to my photobucket album Bicycle Frame Jigs:

http://s978.beta.photobucket.com/use...postlogin=true

I'm also working on a Bicycle Frame Jig, that can be used for one style frame ie / meaning production frames as well as an adjustable Bicycle Frame Jig, this is a work / design in progress.

Thanks again to Culvercityclassics & Sportscarpat for the inspiration / design / style of frame jig's that they've designed.
Sportscarpat for his idea of using an engine stand Jig for rotisserie spinning the frame around, and CulverCityClassic's design using the C-Channel / Uni-Strut inexpensive frame jig!

C.H.