Winston Hannaway
1970s-style 'chopper' bike
St Patrick's College, Wellington
Year 11 Materials Technology, three-term project
Teacher: John Davidson
Winston was challenged to design a piece of recreational equipment suitable for Year 11 boys. Having designed and built a chopper bike at home the previous year, he decided to build on this experience to create another chopper of even higher quality and finish. Winston's project involved modifying the frame of a mountain bike, and required him to be able to accurately measure, redesign, cut, weld, grind, and repaint the frame.
Winston wanted a bike inspired by 1970s chopper design – something that was well balanced visually and physically, and comfortable and safe to ride – and researched a wide variety of designs and styles of bikes and motorcycles. Initially, he thought about a three-wheel trike design, but after researching the concept and finding out about the complex drive mechanism required, he decided that he had neither the time nor the resources to do this.
Four key areas were considered in the design: the length of the forks, their rake (angle), the shape of the handlebars and the style of seat. After disassembling the mountainbike – something he already had expertise in – Winston photographed its frame, and drew his ideas on paper.
Using accepted engineering practice and advice from his teacher, Winston designed and fabricated extended forks and altered the frame's rake angle. He bought a seat and created support struts to secure it at the rear. Assembly was made more accurate by making and using a system of jigs. He used automotive body filler to finish the welded and ground joints to a high standard.
Winston tested the bike, then disassembled it and prepared the frame for painting. After sanding and masking some areas, such as exposed threads, he primed it with an enamel primer, and applied several coats of paint. Care was taken to use a protective face mask and to keep the painting space as well ventilated and dust free as possible.
Reassembled, the bike was a tribute from 2007 to the 1970s.
Teacher comment
Winston's project was a great success, due to his attention to detail, planning, organisation and diligence. The end result is exactly what he was after – a high quality, safe and stylish chopper bike.
