CR500 Steel to Alloy frame conversion.

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sat Oct 27, 2012 3:41 pm

laidback wrote:And yes you are nuts... 8)


In the CR500 community we prefer to be called "hoon". ;)

They even have an annual CR500 hoonfest in the USA :kuda:


yzr750 wrote:
Sulli wrote:Bty that head is running .06mm squish? or .07mm cause that will make it peakier :lol: :roll:


if that was running .06mm or .07mm squish it would last about 2 seconds.


I dont know what the squish is TBH, i was told it was machined for more bottom end powa, the guy does dozens of these and is well respected in the CR500 "hoon" community 8)

When I see him online I will ask what it is or I could wait until it is installed.
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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sun Oct 28, 2012 7:58 am

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Re: CR500 Steel to Alloy frame conversion.

Postby laidback » Sun Oct 28, 2012 8:23 am

Fkn mental... :shock:

I can see a rush of conversions coming up... 8)

Go the smokers :kuda:
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Re: CR500 Steel to Alloy frame conversion.

Postby timmyrocks » Sun Oct 28, 2012 8:59 am

Haha wheelies quite easily ay :P lol

When am I going to see it at gingers jonno :) :) missed my fix this year, hopefully early next year we can get a group?

Where's your video cam with you swearing your head off :P
anyone can go fast in a straight line,,,,

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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sun Oct 28, 2012 9:05 am

I cant swear in swedish :lol:


Here is a nice little read on the KX500.
http://www.dirtbikemagazine.com/ME2/dir ... 3C382A19F5

Image

"A fuse looking for a light."
"Unrideable."
"Violent."


:kuda:
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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Tue Feb 12, 2013 10:32 am

Update.

Now I will be at home more often i have made a start on the CRF alloy frame.

The challenge is to complete this by the 1st week in April ready for GC which is well before this Xmas as someone with a Jag suggested :P :lol:


Here is a few pics coz' we all like photos 8)

frame1.jpg
The inspiration
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frame4.jpg
This is very light
frame4.jpg (221.31 KiB) Viewed 7396 times



Ready to start with the dremmel

frame3.jpg
Dremmel time
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Frame kit on order.

frame kit1.jpg
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frame kit2.jpg
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After many months reading about how many have done this I had narrowed it down to a 1/2 dozen different ways, however I decided to get this kit (which has only been recently available) which comes with well illustrated instructions, this takes so much work or rework of original components out of the equation, it is so simple. This bloke makes all the parts needed and ships worldwide and quickly by all accounts. Around the $350 shipped which is reasonable considering the Y piece is billet and the rootaround factor of the other methods and provides better support.

Really dont need to make anything it is simply a cut and replace job. There is a bit of fiddling about with modifying radiator outlets, relocating the CDI, mod airbox, different swingarm bearing spacer lengths and removing unwanted frame brackets etc. Anyway I will highlight each step as we get to it.

they say the hardest part is finding an experienced alloy TiG welder willing to do it although i have someone in mind. ;)

I am considering either revitalising the brushed/linished alloy look on the frame or full polishing, this can be done anytime down the track but I think the brushed looks more factory IMO.


Alloy v Steel

alloy steel.jpg
alloy steel.jpg (199.98 KiB) Viewed 7385 times
Attachments
alloy steel 21.jpg
alloy steel 21.jpg (134.74 KiB) Viewed 7385 times
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Re: CR500 Steel to Alloy frame conversion.

Postby timmyrocks » Tue Feb 12, 2013 8:02 pm

Sweet bring on gingers :) :)
anyone can go fast in a straight line,,,,

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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Tue Feb 12, 2013 8:40 pm

Think you can handle a ride Tim?

Even at idle it is menacing :lol:
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Re: CR500 Steel to Alloy frame conversion.

Postby timmyrocks » Wed Feb 13, 2013 12:37 am

Hellll no!!! I'd kill myself hehe
My first smoker is going to be a 150 haha
anyone can go fast in a straight line,,,,

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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Wed Feb 20, 2013 5:48 pm

Compression tests read 145+ over four kicks wide open throttle (140 is min spec I think). For now i will button on the new head until I get the bike built and the budget improves. Waiting on the new cometic head gasket to arrive.

CR (5).jpg
CR (5).jpg (128.79 KiB) Viewed 7332 times


it will file out, no wuckas mate!
CR (1).jpg
CR (1).jpg (128.77 KiB) Viewed 7332 times


New Hinson basket, oem fibres and steels ordered.

Using the steel plates for additional flywheel weight, OEM is best in this application, the Hinson basket has additional holes for better oil flow.
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Re: CR500 Steel to Alloy frame conversion.

Postby the kid » Sat Feb 23, 2013 6:33 am

Cut Cut Cut Cut , Cut the frame :twisted:
Ummmm let me see
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Re: CR500 Steel to Alloy frame conversion.

Postby timmyrocks » Sat Feb 23, 2013 8:14 am

Nice :D
What's the added sensor on the new one jonno?
Clutch basket looks alright lol :P
anyone can go fast in a straight line,,,,

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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sat Feb 23, 2013 10:46 am

the kid wrote:Cut Cut Cut Cut , Cut the frame :twisted:


Measure 20 times cut once and even read the instructions first :shock:

Waiting on USPS to deliver the frame kit then it's all go 8)


timmyrocks wrote:Nice :D
What's the added sensor on the new one jonno?
Clutch basket looks alright lol :P



Thats a dickhead detection device Tim, as soon as it knows there is a newbie riding it will WOT ya ass :lol:






Quite boring really, it is a decompression valve for easy starting, like on a chainsaw it closes when it fires, saves the kickstarter casing and makes life a bit easier.
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Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Tue Feb 26, 2013 7:00 pm

Ready for welding.

I can tell you attacking an alloy frame with a saw doesn't sit well with me but it has to be done, however the great thing about it is the confidence to take on similar projects in the future.

1st stage of welding is to have the main frame done so I can fit the motor, I really am trusting this jig to be accurate for engine clocking, chain alignment and save lots of mock-up time. 8)

frame7.jpg
frame7.jpg (131.59 KiB) Viewed 7266 times



Once fitted the 2nd stage is to prep the mounts for the coil, CDI and exhaust and a few other bits n pieces, then its finishing the fit-up, later on the suspension, plastics/decals and some big $$$ performance components will be done but I want it running for a shakedown ride first. :kuda:
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Re: CR500 Steel to Alloy frame conversion.

Postby Gosling1 » Tue Feb 26, 2013 8:31 pm

lookin' good buddy :kuda:
".....shut the gate on this one Maxie......it's the ducks guts !!............."
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