Joined in 2023 
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63 About this deal
Engine Size: Traditionally minibikes were primarily manufactured with micro-displacement engines (usually around 50cc’s), though in a bid to attract adult riders, larger and larger powertrains have been employed. It isn’t uncommon to see production minibikes capable of 50-75mph speeds right out of the box. And, while the majority of minibike engines will be of the air-cooled, eighth-liter, single-cylinder variety, it’s still worth looking into the manufacturer that produced the engine, what kind of internals and systems it uses (such as its cam setup or whether it’s carb’d or fuel injected). And, just like every other facet of the motorcycle, automotive, and transportation industries, electric powertrains are increasingly permeating the minibike space, making EV models worth a look when shopping. The first step was to figure out the parameters of my tube bender and you will have to fo the same for yours. In essence, this consists of doing a 90deg test bend (as explained in detail on the video series linked above), marking 1" gradations and marking the bend at 10 deg increments until you hit 90 deg. That gave me the Cost of Material (COM) =4.5" for my setup so I knew how much metal to use and where to mark it out. Following my marks too closely won't be exact for your setup so I really suggest understanding the principles before setting off.
The steering yokes (at least I think that's what they are called. The bits that the forks are mounted to) are cut from 6mm steel using an angle grinder / plasma cutter and drilled per the plans (1" hole for the forks. 16mm hole for the steering bolt. The distance between the yokes should be 160mm + enough space to add a couple of washers or bushing, In my case I added 8mm. (I think the plans show it a bit tighter). Spend a decent amount of time ensuring that the wheel is running true with the frame. I didn't have a scientific way of doing this so I just eyeballed it + used a meter rule to help see angles vs. the frame. Bash true with a wooden mallet if necessary.While minibikes admittedly aren’t the most powerful or high-performance two-wheelers, they are nonetheless are capable of delivering a simple, stripped-down riding experience that maintains much of the thrills of full-size motos. The sensation of the wind in your face and the world speeding past you with nothing separating you from the ground is in no way lost on minibikes. On top of being cheaper to outright buy, minis are also far less expensive to register, maintain, and insure.
Spray the frame. I used a bog-standard rattle can (Hammerite smooth / rust-oleum). Seems to look OK. I used a hole saw to notch the tubes (as shown) but those with patience can use a coping file too. I always try to get the best fit I can before welding to get a good strong joint. With all the angles a bit off from the tube bending, this was difficult to do! take your time here and it will pay off (as I should have done), Adjust so that the calliper mount is in a position that you can get a good weld against the rear stay. The only changes I see today in the basic Duddel bug design is, the advancement in engine horsepower by almost 4 times (!), with over head valve engines. And the addition of a transmission. This improvement resulting in a 35mph top speed carrying an adult, and the machine now being wheelie capable !
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Drill some seats for the grub screws on the wheel bearings to grip onto. Without this, the axle will likely move about and also, the screws will mark the shaft meaning you'll most likely never be able to remove it again I delivered local newspapers on my Duddel Bug for a year. Until I was able to buy a "REA:L" motorcycle with my earnings. I still smile from ear to ear as I think of that machine. I had made it myself, and I was proud as punch of it. It was my first major project, and gave me confidence in myself that I could make some cool things. Rather than just dreaming about them. So, before deciding what mini pump to buy, you’ll need to think about a number of factors. How much will it inflate your tyre per pump? How lightweight is it? How easy can you stash it away or mount it to your bike frame? And how durable and versatile is the pump head? Does My Bike Have Presta or Schrader Valves?
What’s more, one can thoroughly upgrade a minibike with aftermarket parts for a fraction of what it would cost to build-out a big-bore moto project. And while it is a somewhat niche scene, there are thriving minibike racing leagues scattered across America (and the rest of the world), giving riders a taste of racing without the exorbitant overhead costs that typically come with two-wheeled competition (not to mention a markedly lower chance of injury). Affordability: We believe that premium quality should be accessible to all, so we offer competitive prices without compromising on the performance and durability of our frames. Unmatched Performance: Experience immediate and precise response as you maneuver through corners and turns with ease.
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It also comes with a gas needle to inflate the sports balls, a fixed belt and holder to attach the pump on the bike, a rubber binding strap to fix the tube, a puncture repair kit and user manual. To make the forks, I did the tightest 'S'-bend i was able to with a 3" CLR die in the tube bender. I would guess yours will be the same. Don't worry about the precision on the width too much. There is plenty of room to adjust things later/add spacers etc. Just make sure the fork legs are the same on both sides As you can see by the result this was a bit of a 'bodge-up' as they say in the U.K, but works great. I have included a template for a cutout for the brake calliper that would be a neater way to do it. Attach the pump to the tyre valve. The hose head can be switched between Shrader and Presta valves easily.
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