Ok, here's the deal with a reliable no-weld chopper. This is exactly how BRC Winter was created. Admittedly, the build was reinforced with welding, but after about a year, I looked at it and realized the weld had come of long ago and I had never noticed.

First thing to do is to collect the ingredients. You'll need a hacksaw, two or three 80's style racing bikes, (one whole bike, one or more frames) and either a hammer or a vice. A vice would work much much better. You'll also need a piece of wood, because whenever you use a hammer on a piece of metal, you never hammer the metal itself, you put a piece of wood (2x4 or something) on the metal and hammer on that, so you don't distort the metal.

First thing you need to do is to find a cheap ass 80's frame. The kind with the type of fork in fig 1. On this kind, there is an oval part near the top.

On this oval part, the top four or five inches are uniform size. Cut like Fig 1, in the center of the uniform part. It should now look like Fig 2, and as you'll see, it's definitely oval.

That makes it a bit tough to extend, so most people don't bother with this kind of fork. However, these tubes weren't made oval, they were made round, so you can round them out again. You can do this in one of two ways to make it look like fig 3. You can use a hammer, which is harder than hell to get it in a perfect circle, or you can squeeze it in a vice, which works fantastic, and creates a perfect circle.

You'll now have a circular end of the fork tube. Do this on both bottom and upper halves of each fork blade, for a total of 4 times, so all the ends are circular. Now that it's circular, you need to hammer an extension on it. The easiest place to get an extension is from another bike's crossbar. There are only a few crossbar sizes on these type of bikes. Find one just a little bit bigger than the circle on the end, and you can hammer it on like Fig 4.

This could make about a three foot long fork, and anything more is a little too long anyway. You'll notice that on most 80's bikes (those pseudo-racing ones with the ram's horn handlebars which are a dime a dozen) there are only about three sizes of bars they use on them, and each one is telescopic with another, although damn snug, which is preferable.

Now..... one thing you may be thinking to yourself is... 'why would I go through all this trouble to create a round fork blade, when I can just cut up a fork blade which is already round?'... well, good question. That's the no-weld part. You see, when you round out that oval fork blade, only a couple of inches will be rounded out. Past that, it's oval again. So when you hammer that extension on, it will be real easy for the round part, and then start to contort for the oval part, and that contorting will keep it on pretty well.

In the end, you get a bike that looks like winter. You can shorten the extensions of course, do it to a different kind of bike, throw a banana seat on, or other stuff to give it a bit more style, but altogether, it is a pretty easy way to give a bike some extended forks.