not completed but not far off

gregrobo · Post by **gregrobo** » April 24th, 2009, 4:20 am

my aim to have a bike that looks like it rolled of hondas production line but with more bling

my build started with a 01 cr500r it was bought in kalgoorlie western australia for 3700 it wasnt running had broken clutch cover other than that in good condition. the donor frame was a crf 250 05 in reasonable condition with the conrod hanging out the front of the barrel

gregrobo · Post by **gregrobo** » April 24th, 2009, 4:26 am

started cutting and put the motor in then decided to remove whole lower cradle

gregrobo · Post by **gregrobo** » April 24th, 2009, 4:45 am

whole lower frame cradle removed

with the frame rails out of the way we could install the motor we decided to replace the whole frame rail to eliminate joins

dads always fitting bits and checking clearance factory pipe fits i think its actually easier to fit on the af that the steel frame

frame rails fit pretty neat

[/img]

i removed the original frame mounts and reused them by putting a compensator underneath them also letting me thicken that part of the frame

gregrobo · Post by **gregrobo** » April 24th, 2009, 4:51 am

owned the bike for under 3 weeks so for and over half way the only jobs left as of friday arvo is to complete air box mods and weld the radiators then stip the frame so we can weld it

gregrobo · Post by **gregrobo** » April 24th, 2009, 5:36 am

its isnt finished this job is a continual mock up in this photo its just all tacked together to make sure it all works the at the end it will be stipped and welded

[/img]

but its coming together well

http://www.youtube.com/user/500bigbore · Post by **Roostius_Maximus** » April 24th, 2009, 6:52 am

looks good

97af · Post by **97af** » April 24th, 2009, 7:12 am

Post the shots on Photobucket....Not all of us are into Facebook.

gregrobo · Post by **gregrobo** » April 25th, 2009, 2:27 am

thanks photo bucket is heaps better

gregrobo · Post by **gregrobo** » April 25th, 2009, 2:31 am

radiators finished today they worked out really well havnt got any finished photos yet

[/img]

going to put a cap on the lower pipe it isnt in the way so cant see why it needs to be cut off and plugged

made an adaptor to fit the crf inet to the cr 500 radiator pipe crf hoses are bigger [/img]

Mik329 · Post by **Mik329** » April 25th, 2009, 5:50 am

Looking good! did you heat the tube prior to bending and what radius is your square tube jig? I have a JD2 tube bender and I'm going to order a square jig to do this as well.

xtremeslide · Post by **xtremeslide** » April 25th, 2009, 6:48 am

That's why i love the CR500's world even watching the same gen

convertion for ages,each bike gives you something different to learn

HrcRacing · Post by **HrcRacing** » April 25th, 2009, 9:22 am

That looks great. I love the builds where the tubing is completely replaced on the cradle. Very nice.

Post by **AlisoBob** » April 25th, 2009, 1:57 pm

Very, very nice.....

juddy · Post by **juddy** » April 25th, 2009, 2:58 pm

Mik329 wrote:Looking good! did you heat the tube prior to bending and what radius is your square tube jig? I have a JD2 tube bender and I'm going to order a square jig to do this as well.

The centreline radius of the frame rail should be 125mm (5 inches) making the outside radius of the jig 112 (4 1/2 ")

gregrobo · Post by **gregrobo** » April 25th, 2009, 7:06 pm

thanks for the comments ,alisobob your bike was the first i saw on this site and was the inspiration for ours and probly a lot of others.
be careful what die you get for your bender most shs benders crease the inside of the bend to form the bend, ours does to. to get around that we used a pipe die with the square rollers i dont have any photos at the moment it also helps my dad owns the fab shop i work at so all the right gear is at hand thanks dad

davo77 · Post by **davo77** » April 26th, 2009, 3:04 am

looks sweet dude. where did you find the tube?

gregrobo · Post by **gregrobo** » April 26th, 2009, 10:24 pm

atlas metals in kalgoorlie had a couple of lengths in stock

"SOLID Bro!!" · Post by **"SOLID Bro!!"** » April 26th, 2009, 11:18 pm

Mik329 wrote:Looking good! did you heat the tube prior to bending and what radius is your square tube jig? I have a JD2 tube bender and I'm going to order a square jig to do this as well.

Mike let me know what degree and tubing that you are going to bend and i'll try it on mine. As I have the same bender and will save you the money on buying the die to bend it with. I tried to bend 6061t6 round tube awhile back and it snapped do to stretching. Just an idea, let me know. It could save you a couple hundee.

Mik329 · Post by **Mik329** » April 27th, 2009, 5:52 am

[quote=""SOLID", Bro!"]

Mik329 wrote:Looking good! did you heat the tube prior to bending and what radius is your square tube jig? I have a JD2 tube bender and I'm going to order a square jig to do this as well.

Mike let me know what degree and tubing that you are going to bend and i'll try it on mine. As I have the same bender and will save you the money on buying the die to bend it with. I tried to bend 6061t6 round tube awhile back and it snapped do to stretching. Just an idea, let me know. It could save you a couple hundee.[/quote]

it's going to be a 1" square .095 wall T-6. probably around 4.5 or 5.0 radius. did you heat your tube before bending? I don't mind getting the square jig as I will probably do more frames down the road if mine turns out as planned.

juddy · Post by **juddy** » April 27th, 2009, 6:04 am

gregrobo wrote:atlas metals in kalgoorlie had a couple of lengths in stock

No shit ?? I searched all over Perth ,Eastern States and had no joy.Mike from TTM ended up helping me out.

gregrobo · Post by **gregrobo** » May 2nd, 2009, 5:13 am

after a week of work 99% finished just need to get some new plastics and some bling bits and its done
ive ridden it today and no vibrations its absolutely awsome have a shake down tomorrow around a three hour enduro track and it sould be ready for some motorcross

gregrobo · Post by **gregrobo** » May 2nd, 2009, 5:24 am

in just over three weeks dad and i turned a 2001 cr 500 r into a crf 500 af
before

to this
i would like to thank my dad for all his help knowledge understanding and patience most of all his workshop and shane for the welding thanks champ my cousin smurf for the crf chassis we will have fun with this bad boy and most of all my wife for her patience there will be more photos to come when she gets a new set of skins and some stickers.

juddy · Post by **juddy** » May 2nd, 2009, 6:26 am

Good work ! What are you doing with the steelie ? PM me if you are going to sell it.Cheers

Wheelie-Gene · Post by **Wheelie-Gene** » May 2nd, 2009, 3:25 pm

That's bad ass man, I love it.

Cool to have the old man help out too.

Post by **AlisoBob** » May 2nd, 2009, 3:41 pm

Wheelie-Gene wrote: Cool to have the old man help out too.

BannedCR500Riders.com

not completed but not far off

not completed but not far off