Choppers Course

Lesson 1 • Safety Fundamentals and Protective Gear

Covers essential rider safety principles and proper protective equipment selection. Establishes a safety-first mindset before any hands-on work begins.

Lesson 2 • History and Culture of Choppers

Traces chopper origins from post-war custom bike movements to modern builds. Establishes cultural context that informs design philosophy throughout the course.

Lesson 3 • Choppers vs. Standard Motorcycles

Compares chopper geometry, weight distribution, and handling to stock motorcycles. Students understand trade-offs that guide every build decision.

Lesson 1 • Hand Tools for Chopper Builds

Covers wrenches, sockets, pliers, and specialty motorcycle tools. Correct tool selection prevents fastener damage and ensures precise assembly.

Lesson 2 • Personal Protective Equipment in the Shop

Details PPE requirements for welding, grinding, painting, and chemical handling. Students match PPE to each task type encountered throughout the build process.

Lesson 3 • Workshop Layout and Organization

Defines optimal bench placement, lighting, and storage for a chopper shop. Proper layout reduces errors and speeds up every build stage covered later.

Lesson 4 • Power Tools and Shop Equipment

Introduces grinders, drills, welders, and hydraulic lifts used in chopper fabrication. Safe operation of each tool is demonstrated before students use them independently.

Lesson 1 • Engine Selection for Custom Builds

Compares engine families by power, weight, and frame compatibility for chopper applications. Students match engine choice to build style and intended riding use.

Lesson 2 • Lubrication and Cooling Systems

Covers oil circulation, wet-sump vs. dry-sump systems, and thermal management. Understanding lubrication prevents premature engine wear in all subsequent build stages.

Lesson 3 • V-Twin Engine Architecture

Examines the V-twin layout dominant in chopper builds, including cylinder angles and firing orders. Students identify V-twin variants and their compatibility with common frames.

Lesson 4 • Internal Combustion Engine Principles

Explains the four-stroke cycle, compression ratios, and power output concepts. This foundation is required before students disassemble or modify any engine.

Lesson 1 • Chopper Frame Geometry Principles

Explains rake angle, stretch, and backbone geometry and their effect on handling. Geometry decisions made here directly influence every downstream component fitment.

Lesson 2 • Welding Techniques for Frame Work

Teaches MIG and TIG welding processes specific to motorcycle frame joints. Weld quality directly determines structural integrity and regulatory compliance of the finished build.

Lesson 3 • Frame Inspection and Stress Testing

Introduces visual inspection, dye-penetrant testing, and load verification methods. Passing inspection criteria ensures the frame is safe before any components are mounted.

Lesson 4 • Modifying and Stretching Existing Frames

Covers cutting, gusseting, and re-welding stock frames to achieve custom geometry. Students apply geometry principles from earlier sections to real modification scenarios.

Lesson 1 • Brake System Design and Installation

Covers disc and drum brake selection, hydraulic line routing, and caliper mounting. Brake system integrity is verified against stopping-distance performance standards.

Lesson 2 • Front Fork Systems and Springer Forks

Compares telescopic, springer, and girder front forks used on choppers. Fork choice affects rake angle, trail, and the visual style established in the frame chapter.

Lesson 3 • Rear Suspension Options

Covers hardtail, softail, and swingarm rear suspension configurations. Students evaluate comfort, aesthetics, and structural demands of each option for their build.

Lesson 4 • Steering Head and Neck Bearings

Details steering head bearing types, preload adjustment, and replacement procedures. Proper steering head setup is critical to safe handling at all speeds.

Lesson 1 • Drivetrain Alignment and Final Setup

Ensures engine, transmission, and rear wheel are co-planar and correctly spaced. Misalignment causes rapid wear and vibration that undermines the entire build.

Lesson 2 • Clutch Assembly and Adjustment

Covers wet and dry clutch designs, plate inspection, and cable or hydraulic adjustment. Proper clutch setup ensures smooth power transfer and prevents slippage under load.

Lesson 3 • Transmission Types and Gear Ratios

Compares 4-speed, 5-speed, and 6-speed transmissions common in chopper builds. Gear ratio selection is matched to engine torque curve and intended riding style.

Lesson 4 • Secondary Drive: Chain and Belt Systems

Covers rear chain and belt drive installation, tensioning, and sprocket alignment. Secondary drive setup directly affects rear wheel traction and drivetrain longevity.

Lesson 1 • Lighting, Switches, and Instrumentation

Covers headlight, taillight, turn signal wiring, and handlebar switch installation. Lighting circuits must meet minimum visibility standards for road-legal operation.

Lesson 2 • Battery and Charging System

Covers battery sizing, stator output, and regulator-rectifier function for choppers. A properly sized charging system prevents electrical failures on the road.

Lesson 3 • Electrical Fundamentals for Choppers

Reviews voltage, current, resistance, and circuit types relevant to motorcycle wiring. This foundation prevents dangerous wiring errors in all subsequent electrical work.

Lesson 4 • Ignition System Design and Timing

Explains points, electronic, and programmable ignition systems and timing procedures. Correct ignition timing maximizes power output and prevents engine damage.

Lesson 1 • Metal Preparation and Surface Finishing

Covers grinding, sanding, and priming metal surfaces before paint or powder coat. Proper surface prep determines the adhesion and longevity of any finish applied.

Lesson 2 • Fluid Fill and Initial Start Procedure

Guides students through filling oil, fuel, brake fluid, and performing the first engine start. Controlled first-start procedures catch leaks and timing issues before road use.

Lesson 3 • Pre-Ride Inspection and Documentation

Applies a structured checklist covering all safety-critical systems before the first ride. Documentation creates a baseline record for ongoing maintenance and regulatory review.

Lesson 4 • Paint and Powder Coat Application

Teaches spray gun technique, color matching, and powder coat oven curing processes. Finish quality reflects build craftsmanship and protects metal from corrosion.