BannedCR500Riders.com

ok man i gotta ask you what size tubing your welder used for the extensions on the frame? i need to find something somewhere that can work for my frame, i never thought it would be so miserable trying to find some...by the way that looks very clean...and you can't even see the welds anyways...going to be a sick bike...

That's looking great man. I especially like the headstay. Very nice.

Way to stick with it!

Balaclava wrote:ok man i gotta ask you what size tubing your welder used for the extensions on the frame? i need to find something somewhere that can work for my frame, i never thought it would be so miserable trying to find some...by the way that looks very clean...and you can't even see the welds anyways...going to be a sick bike...

My welder (s) did just that... welded I used solid bar to fill in my frame section; which by the way came with the frame when I bought it, so I can tell you little about it. It was the same width as the frame section only a little less than a 1/16 of an inch shorter. You can see the diff in this pic!

The billet pieces are 6061-T6 stock that I bought from onlinemetals.com.

what measurement exactly?

Balaclava wrote:what measurement exactly?

1" x 3/4"

thanks man...you have been a massive help to my build...

Thought I would post up a few pics of how my conversion sits at this point. Ordered the silencer today and just wating on a few items from Hondaparts to finish up the airbox. Hopefully the beast will be breathing in a week or two and rolling on new wheels 2 weeks after that Body work and graphixs will be last




Coil and fuel valve


CDI box behind number plate


Still waiting to get my left rad back, here are the mount locations

Very very clean looking

looking good

Looks great man.

looking really good. Wait till you ride it, these things are awesome!

I have bought bikes out of a crate brand new but have never had the pride of ownership you get from riding a bike you built yourself. I actually wash it and change the air filter more than once a month.

Got down and dirty with the airbox this morning. Went with a thin aluminum plate for the airbox. Stock 450 airbox, filter ring and filter. 1998 CR250 boot and outer metal boot ring. Cut the plate to fit with a jig saw and then cleaned the edges up with the Dremel.


Mounted the plate to the front using the top 3 holes for the 450 air filter internal ring, they feel outside of the 250 boot. Stuck teh boot on the carb and fit it in all nice, attached box to sub frame and assembled. Marked out where 250 boot fit, this was after I applied a little heat and got things sitting nice and plumb. Cut hole in plate for 250 air boot and mounted boot to plate.
Outside shot

Inside shot


Mounted plate to airbox, added a couple extra bolt points. Fits nice, once I get the proper bolts and assemble it with silicon I will post the shots of it on the bike
Outside shot

Inside shot
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have you bolted it on the bike yet does it clear the shocker ok

Here it is all ready to go the bike, sealed up inside and out. Used about 3ozs of black permitex


Aluminum filter cage and twin air filter, should have no intake issues with and the big boot and no back fire screen to slow down the flow.


I did have to put a little heat on the top of the boot where it hit the frame, basicly poked the corner in and its holding that shape; only way the boot would move high enough up. Might use a little more heat and shape it for a better cosmetic look.


Clears the shock nice all around; tried to get a pic, but they sucked.


Got the left rad back from getting the bottom outlet turned up, guy did a nice job. Mounted it and filled the system with water to give it a good flush before the Ice was to go in just to find the right rad has a small leak from the top tank

And here it sits; I no parts left on the shelf, but the silencer will be in this week

eyesky2002 wrote:
I did have to put a little heat on the top of the boot where it hit the frame, basicly poked the corner in and its holding that shape

I ground the frame a little on mine to gain some clearance with a similar issue....

AlisoBob wrote:

eyesky2002 wrote:
I did have to put a little heat on the top of the boot where it hit the frame, basicly poked the corner in and its holding that shape

I ground the frame a little on mine to gain some clearance with a similar issue....

I did too, but that corner still hit and threw the hole thing off, said puck it and poked it in!

Nice work on that airbox Eyesky2002.

so the 250 boot fits the 500 carb? can't wait for the bike pics...

cause i tried heat expanding my boot and i ripped it...is there any issues with how it lines up from the box to the carb?

Balaclava wrote:so the 250 boot fits the 500 carb? can't wait for the bike pics...

Yes fits perfect, both the 250 and 500 PJ's have the same inlet size only the bore is different. Nothing is going to line up with the 450 boot pattern, so only thing left to do was make a new face for the box.

wicked man...you fuckin rule...you have single handedly figured most of the 450 conversion out for everyone...that looks sick, i'm gunna give her a tryi...

Balaclava wrote:wicked man...you fuckin rule...you have single handedly figured most of the 450 conversion out for everyone...that looks sick, i'm gunna give her a tryi...

I did not figure out anything, just followed what others had done; only it took a while to have it come to vision in my mind.

eyesky2002 wrote:.... so only thing left to do was make a new face for the box.

Looks familiar.....