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Old 03-20-2011, 02:09 PM   #31
Brunow - 007
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Cool! I like the frame. And it's a Twin

Also i found a great article on my harddrive.

Quote:
'Build your own honda DIRT BIKE'
Everyone, when a child, enjoyed the sotyr of "Jack the Giant Killer." Contained in this story is the pleasing moral that big, brute power does not always win out over smallness, coupled with agility and skill. A case in point: Imagine a person dismay, after spending 1300$ for a hylky, powerful super-racing bike, he's ring-dingin along at what he feels must be a new track record, when, thump, thump, thump... AND ZAP! Past him flies a kid on a honda 100 doing a wheely. If this thought intrigues you... READ ON!
Build your own honda DIRT BIKE
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Old 03-27-2011, 03:54 PM   #32
roninwva
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Plane Ben

Have you had a chance to get started on the 250 yet? Your pictures of the 250 don't come up anymore.
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Old 03-27-2011, 06:01 PM   #33
plane_ben OP
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No, haven't done anything yet. I will post up, starting with the tear down, real soon.
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Old 03-31-2011, 12:52 PM   #34
Abdelhub
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Im currently trying to figure how to make a BSA unit motor fit into a crappy old bultaco frame I have. This is just a for fun project with parts left over. Currently the dilemma is the four stroke motor is just too tall for the two stroke frame. I think my solution is to cut the two lower frame rails and lower the engine 1.5 to 2 inches. Then weld up some mounts and use the engine asa stressed member. Id have to fab up a skid plate too.



as you can see the manifold location would push the carb into the frame...



just a silly idea i have...


Mike
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Old 03-31-2011, 01:31 PM   #35
PSchrauber
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Quote:
Originally Posted by Abdelhub View Post
Im currently trying to figure how to make a BSA unit motor fit into a crappy old bultaco frame I have. This is just a for fun project with parts left over. Currently the dilemma is the four stroke motor is just too tall for the two stroke frame. I think my solution is to cut the two lower frame rails and lower the engine 1.5 to 2 inches. Then weld up some mounts and use the engine asa stressed member. Id have to fab up a skid plate too.

...

as you can see the manifold location would push the carb into the frame...

...

just a silly idea i have...


Mike
Cool project, have seen some 4T Sherpas, mostly they did cut of the upper frame like here is a little bit seen and left the lower frame tubes,
just lowerd these a little bit as seen here:



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Old 03-31-2011, 02:02 PM   #36
Thumpermeister
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Quote:
Originally Posted by PSchrauber View Post
Cool project, have seen some 4T Sherpas, mostly they did cut of the upper frame like here is a little bit seen and left the lower frame tubes, just lowerd these a little bit as seen here:


Very slick looking. It can be done with a bit of work. I recently came across this Montesa-Kawasaki hybrid as well.



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Old 03-31-2011, 02:13 PM   #37
Abdelhub
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Quote:
Originally Posted by PSchrauber View Post
Cool project, have seen some 4T Sherpas, mostly they did cut of the upper frame like here is a little bit seen and left the lower frame tubes,
just lowerd these a little bit as seen here:



That is truly something...

Mike
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Old 04-12-2011, 01:56 PM   #38
Brunow - 007
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A while ago i told about my little cb125... Some like pic's .... SO...

I found a old honda XL125 tank (ebay) and a megaphone (laying around) . After some welding everyting starting to fit!

What do ya think?


From Build your own honda DIRT BIKE
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Old 04-21-2011, 09:25 PM   #39
jesusgatos
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Not a dedicated trials bike, but am building a trials-style trailbike out of a chopped-up CRF450.
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Old 07-03-2011, 04:23 PM   #40
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I got my project off to a good start today. Put the XL up on my table and stripped the fenders, electrical, handlebars, and engine off the frame. Got a good look at what it's going to take to raise the engine. I think it will be pretty straight forward. I'm planning on a 1" raise and removing the lower frame rails and making an alloy skid plate. Relocating the footrests to a trials configuration, shortening the swing arm, and steepening the front fork rake. Anyway, here are some pics of the carnage.





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Old 07-04-2011, 07:43 PM   #41
wilkinsonk
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Sounds like you've got a plan, and I applaud your efforts. Do you have a jig or a frame table you are going to use to make sure everything is straight or do you have another method?
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Old 07-04-2011, 09:37 PM   #42
plane_ben OP
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I have a frame jig available for when I do the steering stem. The rest I'm not to worried about. I've worked it out in my head that I'll do the engine raise before I cut the bottom of the frame off.
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Old 07-07-2011, 10:14 PM   #43
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Got my engine raised 1". first shot is the bottom rear mount cut and rewelded 1" higher. You can also see the bottom rails cut off. Some fab left to tie subframe legs back to bottom cross brace.



These are the two new brackets I made to make up the 1" raise for the rear top engine mount.





The front engine mount, I was able to use the stock mount plates. I just turned them up side down and reversed sides. then I cut the down tube in two places. Bent the upper cut towards the engine, and the lower cut back towards the front wheel. Then welded up. I will strenghten those areas with a diamond patch over each weld.



This last pic is the clearancing of the top frame rail to clear the rear valve cover. I will blend out and the shape corners and add a fill piece.



After all this is buttoned up and pretty, I'll tackle the rake on the steering stem.
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Old 07-08-2011, 02:17 PM   #44
PSchrauber
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This is not a complete conversion more a modification but fit here too I thing.

I could get an old pair of betor forks from France:


After deassembling there was some wear and the stanchions where a little bit pittet and not perfect straight anymore:




The stancions where straightened again and got a new hard chrome plating.

I then got special fork caps and progressive fork springs from Spain:


The fork caps are adjustable:


The lower fork tubes where lightened:



Then I replaced some of the worn out shims and bushings too:


And reassambled the forks, the main difference is to the standard one which are blue I lost about pound of weight because I can now use
modern front fender brackets aut of alloy instead of the steel once.




Then some paint:


Test assembly:


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Old 07-09-2011, 07:53 AM   #45
lamotovita
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Wow, I've got fork envy!
Are the fork brace mounts custom or from another bike?
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