dubious 2005 CRF250 conversion

[dubious01]

First off, I would like to thank Aliso Bob for the site,, Pstoffers for my motor mounts and head stays, and Mick for the engine jig.
I am following Bobs thread for the CRF build, and Pstoffers process with the CR250R build.

Thanks to many others with threads I have read, your insight is very valuable.



2005 CRF250 Donor bike I got for $500, which an excellent deal in Canada.
Came with lightspeed super wide ti pegs, black excell wheels,





Got started on the frame:

Working on the frame in the vice is pretty handy actually.
I am an amateur when it comes to fabrication and welding.


hacked off the old motor mounts















Cut out the Y







Cut the excess out of the Y, and chopped the old welds off it.

The large section was the worst, ther was only about 3/8 on the sides- 1/2" front and back of socket left, Honda ran the weld down in there pretty deep.



Took about 45 minutes with a hand file.
This part is critical IMO, if too much was ground off the socket fit would be loose.
I forgot to take pics of that process.

[AlisoBob]

WOW!! Some one actually left the "doubler" on.....

[dubious01]

school IS cool!
I'm paying attention!

250 2st frame is at welder, should be done today,

and the CRF frame will be at the welder tomorrow night,
I just need to make a few motor mounts, and grind down the main down tube, to fit the Y.

[pstoffers]

[dubious01]

btw,
check out the awesome motors MRE (roostius maximus) built for me.
Normally I would do it myself but work has been very hectic, and I'm glad i sent my stuff to Adam. He has the knowledge, tools, and skills to get it done professionally, with perfection.
Those engine are brand new from top to bottom. all new trans bearings, crank assemblies, top end, and some special performance work too.

here is the link to the approved vendors section

click on link:
http://www.bannedcr500riders.com/board/ ... hp?t=10508

[dubious01]

Cleaned up the frame, made the square tube sections, new lower motor mounts and buffed upo all the rough spots.
Was in such a hurry I forgot to take pics.
I will for sure take pics when I pic up both frames from the welder tomorrow.
I am really excited.
The Gen 3 turned out awesome, and the CRF250 chasis is a thing of beauty!
I did a few things different, my radius square tubing is not the same ID as the original square pipe, so I am gusseting the exterior of the frame. without a mill it was nearly impossible to get the interference fit with billet inserts, and additionally, I could not get it to slide inside the tubes once the Y sockets had the tubes in them and the square pipe was lined up at the butt joint.

Getting really stoked... I have been collecting parts and hanging around here for months, it will be a really nice new years celebration with both bikes done
Motor fits in there real nice!