DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

SEMESTER PROJECT REPORT

ON
DESIGN AND FABRICATION OF
MOTORCYCLE (MODEL)

Session: 2016 -2019

Submitted to: Prof. Dr. Zakariya Butt (Registrar)
Project Advisor: Mr. Awais Hamid Bhatti

Submitted by:
Muhammad Asif Rafiq (BSMT 02161001)

BSc MECHANICAL ENGINEERING TECHNOLOGY

IMPERIAL COLLEGE OF BUSINESS STUDIES

LAHORE

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DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Department of Mechanical Engineering Technology | 2

 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

DESIGN AND FABRICATION OF

MOTORCYCLE (MODEL)

THIS PROJECT IS SUBMITTED TO Registrar

Imperial College of Business Studies
FOR
THE PARTIAL FULFILMENT OF THE
REQUIREMENTS FOR AWARDING THE DEGREE
OF
B.Sc Mechanical Engineering Technology

Assigned by: __________________________

Faculty Member’s Signature

Internal Examiner
Sign: ____________________

Name: ___________________

External Examiner
Sign: ___________________

Name: ___________________

Dean’s Signature: ___________________________

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Dedicated To

Our Dearest and most respected Parents,

Whom efforts and prayers are great sources of strength for us in

every noble initiative

Their love inspired us to the higher idea of life.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Acknowledgement

We are thankful to ALLAH and many different people

for helping us in creating this.

 Gratitude to our families for their trust and

understandings.

 Gratitude to our teachers who are always guiding

stars for us.

 Our friends (who have always been a source of

inspiration) have helped to create a wonderful

academic climate.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

ABSTRACT

This project aims to design and fabrication of model of motorcycle. Recently the
motorcycles are found to be the prevalent trendsetters amongst the younger population around
the globe, be it for commuting and sports. This project also focuses on the steps to be put forth
in building a self-designed motorcycle to give an idea of new design. The main purpose of this
project is to fabricate motorcycle by using mechanical fasteners (automobile hardware)
performing different mechanical processes on it.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Project Title:
DESIGN AND FABRICATION OF
MOTORCYCLE (MODEL)

Group Members:
Serial No. Name Registration No.

1 Muhammad Asif Rafiq BSMT 02161001

Objectives of Research/Study
The objective of this study is to identify the mechanisms, functions, maintenance,
characteristics, and principles of pumps. This project topic would be most informative for
our professional career. It would also be very useful knowledge in our professional life.
After accomplishing, the knowledge about project would be very useful related to job and
would a source of more efficiency in the job. It would also be helpful to enhance our
professional experience.

Proposed Chapters of Study

Proposed chapters for this study are four.

Problems and Limitations

1. Problem in accurate data searching.
2. People do not show their interest while giving their response in
research.
3. Shortage of time and high cost.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

TABLE OF CONTENTS

No. Description Page #

1.1 Introduction 09
1.2 Methodology 10~13
1.3 Final Assembly 14
1.4 Performing Process 14
1.5 Quotation 15
1.6 Drawings 16~18

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

1.1 Introduction

Reconsideration and recreation of concepts and innovative ideas in such emerging

automotive trends play a very vital role in today’s Automotive field and also prevail as
knowledge feeders for the thoughts of present and future designers. Styling a product with
one’s own creative ideas in the first place has undergone dramatic changes over time. The
producers have to attract more customers by meeting all their needs. Creative concepts
may not always give way to customer needs. Product development has various phases.
The first phase is understanding and identifying customer needs which can be addressed
through various aspects like customer survey and interviews about customer’s needs. The
next phase is conceptual design and finding solutions to solve the problems from various
points of view. Some leading motorcycles manufacturers came to know that many young
customer’s preferences are for self-specified and self-built vehicles. This project
concentrates on a demonstrative discussion on building motorcycles on one’s own ideas.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

1.2 Methodology

The methodology of the project includes design and fabrication of the model.

Design and Fabrications

This model includes the following parts that are discussed as follows:

Frame / Chaises

A motorcycle frame is a motorcycle’s core structure. It supports the engine, provides a

location for the steering and rear suspension, and supports the rider and any passenger or
luggage. Also attached to the frame are the fuel tank. At the front of the frame is found the
steering head tube that holds the pivoting front fork, will at the rear gear is a pivot point for
the swing arm suspension motion. In short, this is the main part of the model and of backbone
type of frame. All the parts are assembled with the frame.

Measurements

Material = MS Wire

Diameter of wire = 4mm

Length of wire = 160mm

Number of wires = 2

Both wires are bended at 120o and join together by one side and other ends are separated at a
distance of 35mm. A bush of length and diameter of 35mm and 18mm respectively is used to
support at the bending point of two wires.

Engine

An engine is a mechanical device that powers the motorcycle and it is the most important part
of motorcycle.

Measurement

Material = Mild steel

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Nut = 17mm flat to flat

Bolt = 12mm diameter and 25mm length

It is welded to the frame bush at an angle of 75o

Wheels

Motorcycle wheels are made to cope with radial and axial forces. They also provide a way of
mounting other critical components such as the brakes, final drive and suspension. Generally,
motorcycles wheels are of two types: spoked wheel and alloy wheel. In this model, alloy
wheel are used.

Measurements

Material = ABS

Outer diameter = 75mm

Inner diameter = 10mm

Width = 20mm

Needle built in bearings are mounted over bush of outer and inner diameter and length 12mm,
8mm and 22mm respectively. Further road grips are made on the tyres by using knife cutter.

Handlebars

A motorcycle handlebar is a tubular component of a motorcycle’s steering mechanism.

Handlebars provide a mounting place for controls such as brakes, throttle, clutch, horn, light
switches and rear view mirrors.

Measurements

Material of wire = Mild steel

Diameter of wire = 4mm

The wire is bended at three different points at different angles to give the shape of handlebars.
Also the brake and clutch lever, throttle and rear view mirrors are also attached to it.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Front and rear shock absorbers

Shock absorbers serve the purpose of limiting excessive suspension movement and to damp
spring oscillations. Shock absorbers use valving of oil and gases to absorb excess energy from
the springs.

Measurements

Front shock absorbers Rear shock absorbers

Material = MS wire of diameter 5mm Material = MS wire of diameter 5mm

Length of damper = 80mm length of damper = 50mm

Springs = 50mm, 6mm

Front and Rear Fenders

Riding with fenders will prevent the rain from splashing a streak of muddy water up your
bake, over your shoes and on your face

Measurements

Material = MS Sheet

Thickness = 0.7mm

Front fender sheet = 125mm X 25mm

Rear fender sheet = 150mm X 25mm

Both fender sheets are half rounded at a radius of 50mm and is flatted from one end at 5mm
length to give the shape of mud flaps.

Fuel tank and side covers

A fuel tank is a safe container in which flammable fuel is stored and propelled (fuel pump) or
released into an engine. Side covers are used to cover electrical components or wires.

Measurements

Material = MS sheet

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

Thickness = 0.7mm

Sheet is rounded in elliptical shape and side covers are cut in triangular shape.

Seat, Seat Stay and Silencer

A seat is usually for the rider to ride on it comfortably. A silencer is a part which reduces the
noise coming out of a running engine.

Measurements

Material = MS sheet

Silencer Seat

Buffle and exhaust pipe length = 50mm Sheet = 75mm X 25mm

A wire of diameter 4mm and length 160mm is bended at four different points and used as a
seat stay.

Electrical parts

Strips of 15mm X 6mm with two bushes (speedometer), flange nut of 10mm (headlight), 4
cap nuts of 6mm (indicators) are used.

Foot rest and side stand

Foot rest are provided for the passenger and also for the rider. And side stand is also provided
for the standing of motorcycle at left side of it.

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

1.3 Final Assembly

 Frist of all rear wheel and front fork along with front wheel are assemble with frame
body.
 Then handlebars and its accessories are welded with front fork.
 Front fender is welded with front fork and rear fender is welded with frame body.
 Engine is welded with center bush of frame body.
 Fuel tank, side cover, seat stay and seat assembly are welded with frame body.
 Silencer is welded with engine.
 Rear shock absorbers are welded with frame body.
 Head light and front winkers are welded with front fork.
 Tail light and rear winkers are welded on rear fender.
 Side stand welded with engine from left side.

Finally, all parts are welded together and the model of motorcycle is prepared.

1.4 Performing Process

The following processes have been performed for making this model of motorcycle.

 Cutting process
 Bending Process
 Welding Process
 Paint Process

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 DESIGN AND FABRICATION OF MOTORCYCLE (MODEL)

1.5 Quotation for Model of Motorcycle

Sr. # Parts Name Quantity Price

1 Rubber Wheel 2 600
2 Spoke with nipple 4mm diameter 8 80
3 Flange Nut 10mm 1 20
4 Cup Nut 6mm 4 40
5 Spring 6mm 2 20
6 Bush 60mm x 18mm 1 50
7 MS Sheet 12 in x 4 in 1 100
8 Washer 10mm x 25mm 4 20
9 Washer 5mm 2 5
10 Nut & Bolt 8mm 1 20
11 Chain drive 420 (links) 2 15

Total Parts Price 970/- only

Paint Cost 100

Stickers 30

Total Price of Motorcycle Model 1100 /- only

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