new gen3 conversion

davo77 · Post by **davo77** » August 28th, 2008, 6:25 am

just finishing up my first build (gen3 250) and mounting up the exhaust is the last job as far as mods go.

im using a pro circuit platinum and 304 silencer for a later model steely.
pipe fits no problem but the silencer looks like it needs the stinger section cut and modded

i see pro circuit make a SH cr500 af 02-04 silencer . Has anyone used this silencer on their gen3 conversions and is it a straight bolt up deal?

i will post up some pics of the build when i figure out how to?

cheers

dannygraves · Post by **dannygraves** » August 28th, 2008, 7:52 am

contact Mike from team trubble, he gets good deals on the pc pipes and builds a lot of gen-3s

davo77 · Post by **davo77** » August 31st, 2008, 7:03 am

some pics of the frame mods . (if ive posted them correctly!)

davo77 · Post by **davo77** » August 31st, 2008, 7:04 am

davo77 · Post by **davo77** » August 31st, 2008, 7:04 am

davo77 · Post by **davo77** » August 31st, 2008, 7:05 am

eyesky2002 · Post by **eyesky2002** » August 31st, 2008, 7:41 am

WOW... Very nice work my friend!!!

And the PC 304 silencer did not line up on my 450; it was little long, but the bike did not have the front either. Easy mod for me to shorten the pipe and add the front mounting boss, I think it was meant for the 250 gen 3 frame. Either way Mike is the man for PC stuff!

Ported&Polished · Post by **Ported&Polished** » August 31st, 2008, 9:40 am

On my gen3 cr250 the SH Procircuit pipe and silencer fit perfectly with no mods, complete bolt on system.

ISBB · Post by **ISBB** » August 31st, 2008, 12:58 pm

looks like you built your own Y.. Looks good

HrcRacing · Post by **HrcRacing** » August 31st, 2008, 2:33 pm

Great job man.

quantum500 · Post by **quantum500** » August 31st, 2008, 9:31 pm

Hope you didn't weld it in the kitchen. Burn marks on the floor are hard to get rid of! Awesome job. More art than mechanics!

davo77 · Post by **davo77** » September 8th, 2008, 12:23 am

Thanks for the replys , my computer has been down for a week so i havnt been able to log on.

Im pretty happy with the fabricated y section, i have heaps of pipe clearance, but it was alot of work and next time i think i will reuse the origional y and bend up some new cradle tubes.

I fabricated new lower tanks for the rads so i could move the y up a little more for pipe clearance and move the outlets as required.

And, i would have built the whole thing in the kitchen if i could talk the wife around

Post by **AlisoBob** » September 8th, 2008, 2:44 am

davo77 wrote: I fabricated new lower tanks for the rads so i could move the y up a little more for pipe clearance and move the outlets as required.

Friggin' SWEET!!!

Good job, Dag.....

teemtrubble · Post by **teemtrubble** » September 8th, 2008, 8:49 am

Nice job bro

eyesky2002 · Post by **eyesky2002** » September 8th, 2008, 9:13 am

Looking good!!!

lewisclan · Post by **lewisclan** » September 8th, 2008, 9:15 am

davo77 · Post by **davo77** » September 9th, 2008, 4:19 am

Thanks for the comments guys.

Those rads were a pain in the ass to weld. I had to run the tig torch over the joints a couple of times to burn out all the impuritys before adding any filler material.. Was worth the effort though to get the y up a little higher

cheers

juddy · Post by **juddy** » September 10th, 2008, 4:28 am

Nice work David.Not sure if this will work but gonna try show you the frame rails I made,also the die I made to suit the pipebender to bend radius.For anyone willing to do the same its a 112mm (4.5") outside radius for the die giving a 5" centreline radius for the frame rail.I will get stuck into this job in a few weeks time when I have time off work for knee surgery.

And Dave I think you do ok with your wife letting you strip the bike in spare room

Nate · Post by **Nate** » September 10th, 2008, 4:35 am

Looking good!

davo77 · Post by **davo77** » September 10th, 2008, 6:39 am

Hey Judd,

Cradle tubes came out sweet, looks like theres minimal distortion in the bend.
That frame should look totaly stock when done with no joins in the cradle at all.

Is that one of my tubes pictured in the bender??

juddy · Post by **juddy** » September 10th, 2008, 7:37 am

Gday David,yep that would be one of the cradles for your next project.Yeah they came out spot on.Will look factory,Ill make compensating plates for my mounts from that 6061 ally square tubing so will have no weak points at all.

Post by **AlisoBob** » September 10th, 2008, 8:03 am

Go Aussies, Go!!!

teemtrubble · Post by **teemtrubble** » September 10th, 2008, 9:44 am

juddy That material looks just like the stuff I use!

HrcRacing · Post by **HrcRacing** » September 10th, 2008, 11:03 am

teemtrubble wrote:juddy That material looks just like the stuff I use!

Don't you heat treat it before bending Mike? Any problems if you don't?

teemtrubble · Post by **teemtrubble** » September 10th, 2008, 11:50 am

We anneal before bending and heat treat after final assembly and welding.

I sent that material to OZ

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new gen3 conversion

new gen3 conversion