BannedCR500Riders.com

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Looks like you are jumping in head first! Glad to see another build getting started. Been rather quiet around here it seems in light of recent revalations.
I'm getting ready to post some on my 03 crf450. I would suggest you slow down and study before doing a lot of cutting. You might think of another way to do something and not be able to if you've cut some place you shouldn't have. Also, some might disagree but, I wouldn't be doing any grinding in areas that are going to be welded. Use a saw or rotary file and stainless wire brush. The abrasive grit can get embedded in the aluminum.
This has been the most helpful thread for me.
http://www.bannedcr500riders.com/board/ ... php?t=1170
eyesky did a great job of putting his build out there and turned out pretty dang sweet if you ask me.

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I dont think your radiator hoses are going to flow too well....

I used a cutting wheel for everything and then cleaned it up with a nicholson aluminum file (doesn't clog). Best 15 dollars I have ever spent.,

ktm 620 wrote:got to fined some aliminiam for the exstension

Good luck with that. That frame has the odd ball rectangle. I bought some oversize bar from onlinemetals and milled it to size. Left was the original size. Two on the right are the size of tube.

nmdesertrider, where did you get the file at? I'm going to be hand fitting my motor mounts and that could come in handy

Santa Fe Tool in albuquerque- if you don't want to drive out here try online

http://www.google.com/products?client=f ... ision&cd=1

dont qoute me but i swear i seen that file at home depot

nmdesertrider wrote:I used a cutting wheel for everything and then cleaned it up with a nicholson aluminum file (doesn't clog). Best 15 dollars I have ever spent.,

If you dont file it, the debris from the cutting wheel embeds in the aluminum, and it welds like shit.

Buy the file. Good tip Dez.......

ok got some more done today
i made the frame exctensions by hand using a junior akso and a ali file i made them out othe solide tubing ruffly about the same size as the frame tubing thanks for the advise ke 336 the exctensions extend in the tubing about a inch on the top and abought a inch and a halfe on the botem after i made them i got the y siting wher i wanted tok a bit othe peswading with the old amer but got ther in the end then i jaket the frame apart and put the exctensions in then i test fitid the engine plenty othe clearance for the exshuest flange bolts now i got to make some moter mounts any idias pleas in wich way i shouild do them? and olso how shouild i space the swininarm wat lenth spacers shouild i yous? any info walde be great i will post some new pics wen i get a chance chow for now

use stock honda bushings and collars. left (sprocket side) use
#52142-KZ4-J40(54mm) right use 52141-KZ4-J40(59mm)
can't help on the mounts just yet. i'm working on the lowers right now.
I can tell you the bottom frame tubes are running at approx. 6deg. angle.

ok hoons got some more done the last couple ov weeks but athent been posting as been wayting for some parts well i got the engine mounts made top and botam spaced the engine with the honda parts left (sprocket side) use
#52142-KZ4-J40(54mm) right use 52141-KZ4-J40(59mm)
i redone the frame tube exteintions as was not compleatly happy with them so made some new ones much beater than the first ones
will post some pics tomorow before i take it to the welder ? any idias on the frount exuest are welcome

ok years the updated pics i am triing to get a set ov 01 rads then i got to figuer out the head stay and air box mode then exuest mounts
i made some coil mount just got to put a fred in them and weld them to the fame i also had to make some new top engine mounts has the ones i made wear not to goog so i made some new ones
i have halso done the tank mod wich was thery esey just boild some water put in the tank got a heat gun heatid it up slowly and got a claw hamer uesd the ruber handel at the botam and pushed up slowley toke no more than 5 minitus but be carfule as can go rong esley got plenty ov room with the shorty plug can change plug with out taken the the tank off

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