Project Rebel Chop

[cTc]

This is the bike I am working on, I am stretching the rear 6" to give a longer reach, and a few other cool mods.

http://www.choppertowncustoms.com/g5.jpg

Those ugly stock bars are gone and replaced with drag bars, having some custom pipes bent, a 4" stretched tank will be used and a rear fender that I am keeping secret for the moment. If it works like I hope it will be the sickest rebel on the road.

[Drzlars]

Hey CTC nice custom work. I own a 87 450 Rebel & i'm looking into making some modifications. I was checking out your homepage & saw your Rebel chop project 10/18/04. I'm most interested in changing my rear fender too & need to know if i where to buy a rear fender is it a universal fender i would be looking for? And is the rear fender on your bike a universal fender? And from whom did you purchased your fender from if you don't mind me asking? Also were did you purchase your Rigid Seat from? i've been looking for a seat like that to replace the original Rebel seat. I also noticed that you had removed your rear shocks & had replaced them with some kind of a bar, what type of bar is it? & can it be had at any hardware store or online site? I'm looking forward to your reply & if need be may i tap you for more infor as the need arises as there's very little infor on how to customize out there especially when it comes to the Rebel?

Thanks for any infor & help you may be able to provide.

Drzlars

[cTc]

The picutre there is of the bike as I bought it, so poor soul had no idea what they were doing when they started it. The rear fender if you want to call it that is acutally a plastic fron fender from a dirt bike screwed into the seat pan. Yes the person I bought it from was very stupid.

I am lucky enough to have access to a metal shop through a friend, I get all kinds of cull pieces. To do a hard tail all you need is a 1/2" thick piece of steel about 2 inches wide, measure for the mounting holes and get the desierd length.

The seat you see there is stock rebel. YUK, I have bent a seat pan from 3/32" aluminum and have attache the foam, I am in the process of shaping it now. I wish I had more time to devote to it.

I also added drag bars instead of the stock pullbacks

Here are some pics of the risers installed. Sorry for the bad pics, time for a new digicam.

www.choppertowncustoms.com/riser1.jpg
www.choppertowncustoms.com/riser2.jpg
www.choppertowncustoms.com/riser3.jpg
www.choppertowncustoms.com/riser4.jpg
www.choppertowncustoms.com/riser5.jpg
www.choppertowncustoms.com/riser6.jpg
www.choppertowncustoms.com/riser7.jpg
www.choppertowncustoms.com/riser8.jpg
www.choppertowncustoms.com/riser9.jpg

I have a new rear end at the welder that will be a hard tail that bolts on and off. He is taking his sweet time, he owes me a favor, so I guess I will wait. It will make the bike loo very cool.

[Drzlars]

Thanks CTC for the infor & the pics, really appreciate it. I'm looking forward to seeing some more pics of your work.

Droz

[Drzlars]

CTC, were did you buy your Risers & Drag Bar from? & what's the brand name on them?

Thanks

[cTc]

Use this link

http://www.crc2onlinecatalog.com/chopper.htm

They are about half way down the page, $12.95

[Are (yes it is my name!)]

[quote="chopper_town_customs"]
The seat you see there is stock rebel. YUK, I have bent a seat pan from 3/32" aluminum and have attache the foam, I am in the process of shaping it now. I wish I had more time to devote to it.

How are you thinking of making the mounting of the seat pan? Im also going to make my own from aluminum plate, and im not quite sure how to mount it in the front because the stock seat has sort of a stick or something coming out underneath. maybe you can send some pics?

[cTc]

before I attached the seat foam, I drilled 2 holes in the back and 2 holes in the front.

After I drill them I put a 7/8" bolts in and attache with a thin nut and lock washer. I plan to attach a piece of aluminum bent to fit the front mounting point. and in the rear, I drilled the holes to line up with the stock mounting bracket.

The bolts are probably going to break free and spin if I have to attach and remove the brakets more that once, but I dont plan on having to do that.

[Are (yes it is my name!)]

did you use foam from a sock seat? and how are you shaping the foam? do you use a angle grinder or a skissor or something? My dad built his own seat in his hot rod, but he had to get the foam lasercut.

[cTc]

I bought the foam from a local upholstery shop, it started about 2" thick, i have a razor blade that is about 4" and I am using it get the genral shape I want, then I may have to use something else for the interior contour.

[Drzlars]

Use this link

http://www.crc2onlinecatalog.com/chopper.htm

They are about half way down the page, $12.95


Thanks again CTC for the infor.

Drzlars

[cTc]

No prob...... I like the look of the risers on the bike, but it will be a while before I get to ride it. But I will post feedback on them after I get to try them out.

[Drzlars]

CTC, do you happen to know what the width of the Rear Fender on a 450 rebel is? I need to place a fender on there & want to make sure i get the right width. I've got my eye on a Skirted Wide Universal Rear Fender, it's comes in 8 1/2" & 9".

Thanks

[cTc]

I have a spare 450 rear fender, I will measure it this morning and let you know.

[Drzlars]

I have a spare 450 rear fender, I will measure it this morning and let you know.

Great! Thanks man.

[cTc]

The fender I have measures 7 3/4" inside edge to inside edge. So most should be close to that, give or take 1/4"

[Drzlars]

The fender I have measures 7 3/4" inside edge to inside edge. So most should be close to that, give or take 1/4"

Hey man thanks again. Now if i could only find a rear fender with those measurements. Any online sites that you know of were i might be able fine a flat fender with those measurements? I'm be using the side swing arms to attach it.

[cTc]

The best I can do on a flat fender is $49 + shipping. I use 16 ga rolled unfinished flat fenders. 8" wide and 1 7/8" deep. no chain relief

You will likely find a better price somewhere, but i would be glad to order you one. would take a week to me and probably about the same to you.

[Drzlars]

The best I can do on a flat fender is $49 + shipping. I use 16 ga rolled unfinished flat fenders. 8" wide and 1 7/8" deep. no chain relief

You will likely find a better price somewhere, but i would be glad to order you one. would take a week to me and probably about the same to you.

I may take you up on that offer. I'm going to check around some more & see what i can come up with.

Thanks

[Drzlars]

The best I can do on a flat fender is $49 + shipping. I use 16 ga rolled unfinished flat fenders. 8" wide and 1 7/8" deep. no chain relief

You will likely find a better price somewhere, but i would be glad to order you one. would take a week to me and probably about the same to you.

CTC, if you go too the Honda Rebel The Unoffical Rebel Forum & on the top of the Forum Page click onto "Rebel Photo Gallery" & it will take you to another page, & on the left hand side of the page click onto "Rebel Choppers", & look for the photo that says "A 1986 Honda 450 Rebel Hardtail", you'll know which one it is by it's painted red rims & red flames on the black gas tank. Can you cut me a rear fender like that? I'm going to bolt it directly to the swingarms & do away with the chrome fender struts that hold the original fender in place. I will also leave the stock shocks in place so it stays a softail. You think that would work? I'm open to any other suggestions you may have.

Thanks

[cTc]

Not to say that you could not do that, But that swingarm is a long way down. You could however come up with a design to mount in the area of the shock mounts, and keep in mind it would have to be mounted high enought to keep the tire off of it, to clear the suspension travel. If you convert to hardtail, that will not be an issue.

That particular 450 pictured. is probably my most favorite chop I have seen.

[Drzlars]

Not to say that you could not do that, But that swingarm is a long way down. You could however come up with a design to mount in the area of the shock mounts, and keep in mind it would have to be mounted high enought to keep the tire off of it, to clear the suspension travel. If you convert to hardtail, that will not be an issue.

That particular 450 pictured. is probably my most favorite chop I have seen.

Your right there, that is one find custom job. Do you know how that fender was put on & if brackets were use? Or did he just bolt it directly to one of the left over holes were the chrome fender strut or what some people call rails that hole up the fender use to be?

[GearJammer]

Are, An electric carving knife can be used for shaping the foam. I've used a serrated blade (more of a large bread knife) but it didn't work as well. With the electric carving knife, you'd have more control for cleaner, straighter cuts.

Another option is to remove the seat cover, then dip (not saturate, simply dip) the seat pan & foam in a bucket of water & then put it in the freezer for a couple of days. Remove the "frozen"-foamed seat pan & then shape the foam with a good straight-edge of your choice. If it thaws out before you're done, simply do another dip 'n freeze.

Drzlars, Another good source for flat fenders is a trailer supply yard. You should be able to find varying widths, lengths & radius' on the cheap. Just want to make sure that you get the right radius for your rear wheel so that it will follow the circular contour of the rear wheel evenly.

[Drzlars]

Thank you GearJammer for the infor on the fender, much appreciated.

Drzlars

[Are (yes it is my name!)]

What ever happend to the "rebel chop" ctc ? Did you sell it?

It might be possible you've mentioned it earlier, but i cant remember.... :lol:

Are ;)