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Project

American chopper Gas Tank and Final Assembly

VVishnu Boini6 May 2020

1.Fuel tank

Procedure:

Change the names Front plane to Mid plan fuel, Top Plane to Bottom plane fuel & Right plane to front plane fuel.
Select the mid plan fuel and insert the sketch with given directions.

Select the midplane fuel and draw a horizontal construction line of 831mm to left and vertical line of 441 from the endpoint of verticle line.
Sketch as shown.

Now make a reference plane by selecting the front plane fuel and the right endpoint of the spline.
Select the new plane and draw a spline as shown.

Click on surfaces and sweep the surface along the curve as shown.

Select the bottom plane and draw the splines as shown.

Make a reference plane by selecting the midplane and the left endpoint f the gas tank and sketch on the plane.

Select the midplane fuel and draw a spline as shown.

Select the front plane fuel and convert the curve and make it for construction and draw a straight line connecting left endpoint of curve and the top point of fuel tank and select the curves options and intersection curves and convert last two curves.

Now select the surface loft and make a surface loft as shown.

Select the bottom plane and sketch as shown.

Now select the midplane and draw a spline od 6point as shown, and select the curves option and intersection curves and select the last two sketches.

Now select the boundary surface option and right-click mouse and select the selection manager and select the upper curve and make selections as shown.

Mirror the bodies along the midplane and knit all the bodies together.
Now select the bottom plane and ctrl select both the edges and offset 30mm and draw a3 point arc and give dimensions as shown and power trim.

Now go to features and curves and select the split lines option and select both bodies.
Now select the extrude surface option and select the two faces and extrude 25mm and apply a fillet of 20mm to the edge.

Select the boundary surface and do as shown.

Now select the loft surface and select the two edges and guided curve and make a surface.

Knit all bodies together and make them solid.

Apply 5mm fillet to all edges. select the midplane and sketch as shown.

Select the front plane and sketch as shown below, and swept cut along the path and apply a 2mm fillet for the inside edge.

Apply appearances for full-body painted car seina and fro seat fabric, cloth, grey.

2.ASSEMBLY

Procedure:

Open SolidWorks and open all the parts of the chopper.
Now click the new file and open assembly, click on insert option and select the chassis, and click ok then again insert option and select the engine.
Expand engine menu bar and select the front plane of engine and front plane of assembly and make coincident.
Select the face of engine stand and the face of chassis and make them coincident.

select the bottom front face of engine and chassis and give dimensions as shown.

Now insert pedal and Select the extrudes of the pedal and the holes of the stand and make them concentric and select the right face of the pedal and left dace of the stand and make coincidence.

As the exhaust interfered the pedal opens the engine part and make the sketch changes as shown. and save the file and open assembly, now there will be no interference.

Mirror the pedal using linear component pattern and select the mirror option and do as shown.

Insert the kickstand and select the top face of the kickstand extrude on the chassis and inside tope face of the kickstand and make coincident, select the hole on the chassis and circular extrude of the stand make concentric and select the midplane of the kickstand and left face of the chassis and give this mates.

Now insert the transmission belt and make the larger inside face of the transmission belt concentric with the larger pulley of the engine.
Now select the mate option and advance mate width, select the both side faces of the transmission belt and bothe inside faces of pulley.

As the smaller end of transmission, belt intersect modify the belt dimension to 61.5mm dia, select the top face of the belt and face on the engine and five an angle of 7degrees.

Now insert the Oil tank and select the bottom face of the oil tank and top of engine back and make coincident, select the bottom edge of the oil tank and fillet edge of the engine back and coincident.
Now select the midplane of oil tank and midplane of chassis and make coincident.

Now insert the rea wheel and rotate 3 times in Y-Direction and select the hole of the wheel and shaft of the chassis and make concentric and select the Right plane of the rear wheel and midplane of the chassis concentric, and select the right plane of chassis and front plane of rear wheel and make them parallel.

Select insert and click on the rear fender and rotate 3 times in Y direction and 1 time in Z-direction and select the round edge of the fender and any circle on the rear wheel and make them concentric.
Select the midplane of fender and midplane of chassis and make them confident, select the vertical plane of the fender and right plane of chassis and make them parallel.

Now insert the chain and select the mate option and advance mate, width option And select the inside faces of the chain and outside faces of the sprocket and ok.
Expand the chain menu and show the sketch and select the rear curve of the chain sketch and the circle of hub and make them concentric and select the Centre plane of the chain and bottom plane of the chassis and make them parallel.

Now insert the gas tank and select the front plane of gas tank and plane-2 of chassis and give a distance of 5mm.

Select the bottom plane gas tank in chassis and bottom plane in fuel tank and make them coincident.
Select the midplane of the gas tank and midplane of chassis and make them coincident.

Now insert the front fork and select the extrude of the front and inner circle of the chassis and make then concentric.
Select the mate, advance mate select the width option and select the inside faces od upper and lower triple clamps and the upper and lower faces of the chassis.

Go to advance mate options and select the front plane of the fork and midplane of the chassis and give them angle dimensions with -30 to +30.

Now insert the front wheel and rotate in Y-direction select the inner hole of the wheel and bottom rod of the fork and concentric them and create a midplane for and coincident it with right plane of the wheel.
Now select the VIEW PLane in the fork and front plane of the wheel and make them coincident.

Now insert the front fender and rotate one time in Y-direction and select the VIEW plane of front fork and the verticle plane of the front fender and make them coincident.
Select the centre plane of fender and top plane of the wheel and make them coincident.
Select the midplane of the fender and right plane of the front wheel and make them coincident.

Select the chassis and chain and isolate them and sketch on the back face of chassis and split it go get rid of interference with chain and fillet with 3mm.zi

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