Quickly grabbed some 6061 stock from a local metal shop and got started.
![Image](http://i773.photobucket.com/albums/yy14/Duzy500/044.jpg)
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![Image](http://i773.photobucket.com/albums/yy14/Duzy500/049.jpg)
![Image](http://i773.photobucket.com/albums/yy14/Duzy500/057.jpg)
![Image](http://i773.photobucket.com/albums/yy14/Duzy500/018-1.jpg)
![Image](http://i773.photobucket.com/albums/yy14/Duzy500/015.jpg)
Cut some triangle plates and drilled them for front and lower mounts then bent the lower ones to fit.
Used my table saw to cut 1.5 by 1.5" stock. made slugs to fill gaps. Cut down 1/2" on each end to slide into the existing tubes and rounded edges with a die grinder.
Used straight grinder to hog out the inside of the Y section and slightly grinded the front of the down tube till Y slid on about 1/2"
![Image](https://bannedcr500riders.com/images/auto/9becdc846f04addf7194c5fe44ca1237.jpg)
![Image](https://bannedcr500riders.com/images/auto/d726dd4009621db8e7abe1c5544bb8d5.jpg)
Cut a chunk of 3/4 plate and shaped it to form the shock tower. Then cut and bent two plates for the head stay. I only drilled the motor side of the plates and drilled the chunk that was to be welded.
once welded I bolted on side and shot spray paint through the mount onto the plate, then drilled out where painted. Then did the other. Only way I could think so everything would line up.
![Image](https://bannedcr500riders.com/images/auto/00d4ec5d5c5f99cc19a73310266c705d.jpg)
![Image](https://bannedcr500riders.com/images/auto/1d5d9b90b67a8bf51186fc3bcea59ed5.jpg)
Once my buddy BABLE got everything was welded up I polished the whole thing with some mothers and a turbo ball. Might have been cheating but I don't have the patience for that! I'm a 27 year old poor guy... I just wanted to ride the damn thing!
![Image](https://bannedcr500riders.com/images/auto/e26b8c50e2b4d902ae381bed40afa0ae.jpg)
![Image](https://bannedcr500riders.com/images/auto/cf43fff6de17e2ed26af18fa03e64930.jpg)
Mounted the coil on head stay with notched and drilled towers.
![Image](https://bannedcr500riders.com/images/auto/950e05ce297ebf2accef7970bf8e242e.jpg)
Formed the tank with heat. Thanks Bob. Used 98 250 air boot. Thanks Danny.
![Image](https://bannedcr500riders.com/images/auto/8f30083e53e6ae807d45bf05cf22aef4.jpg)
![Image](https://bannedcr500riders.com/images/auto/6e7b6aa0fddd83621deec95fbdcec903.jpg)
Greased linkage, made exhaust mounts reassembled and pounded it till I was so gassed out I couldn't hang on any more. Handles incredible and first day out it was predictable and easy to ride. FAST is what you could call it.
![Image](https://bannedcr500riders.com/images/auto/76ae03443a12e1fb45ba90a1e4fa6b02.jpg)
Five tanks in and no cracks no vibes and nothing but smiles! Sorry about the long post but had to show people who would appreciate it. My friends are all Bitches and don't really care. I'm proud of it and glad I learned so much from this site.
Anybody see anything you would have done different?
Any questions? Glad to help anyone, least I can do for all the help I got from you guys.