BannedCR500Riders.com

ShanMan wrote:the down side is that you removed a significant portion of the "footprint" of the weld....also called contact patch or surface area. In the world of welding, particularly welds put into shear, surface area is a key component. Additionally, the reason the factory weld is curved is to give the weld miltiple directions to resist said shearing loads. if you ground down the Y section so that the weld is now only going to be straight across, I would strongly suggest you make sure the Y section and the frame downtub e are butted together along a physical shoulder, and also that you consider putting a backing plate style brace over the joint to reenforce it. Did you not see Iggy's frame failure? The frame sees a ton of compressive force at that location if you case a jump, and compression along those members equate to almost pure shear on the weld.

uuuuhhhmmmm, X2... I think
yeah, thats why on mine I cut along the oem weld and left everything else the same. the rad mounts are overkill anyway, and honestly if I were give the choice of having a rad giggle until I got back to camp or a craddle split open, I think I would sacrifice the rad.
also, I kept the down tube as long as possible to keep as much overlap between the Y and down tube as possible to reduce the stress on the weld for side loads and vibes. this way all the weld is doing is keeping it from pulling off, but is not the one point taking a beating form all sides.

ShanMan wrote:the down side is that you removed a significant portion of the "footprint" of the weld....also called contact patch or surface area. In the world of welding, particularly welds put into shear, surface area is a key component. Additionally, the reason the factory weld is curved is to give the weld miltiple directions to resist said shearing loads. if you ground down the Y section so that the weld is now only going to be straight across, I would strongly suggest you make sure the Y section and the frame downtub e are butted together along a physical shoulder, and also that you consider putting a backing plate style brace over the joint to reenforce it. Did you not see Iggy's frame failure? The frame sees a ton of compressive force at that location if you case a jump, and compression along those members equate to almost pure shear on the weld.

Basically i followed Algava's build on the other site.

http://cr500riders.com/cgi/yabb/YaBB.pl?num=1212913934

I am pretty sure i removed just as little weld as he did, and not once in that entire build does anyone mention that fact. I personally think it looks alot nicer with a horizontal bead instead of an arching rainbowish type bead. I will discuss this with my welder and we will figure out the best method to prevent such a failure.
I was thinking of showing my welder this picture from Chachi's gen3 and seeing if he could do something like it...think it's possible with the stock Y?

ok i'm probably going to the welder either today or tomorrow, and i need to know if my pipe will bolt up to the existing 250 pipe mount on the cradle below the front motor mounts? I would obviously check but it seems i have lost that bracket piece when i crashed my other bike...if anyone knows off the top of their head if i have to relocate it or not it would be appreciated.

Got the spacers in

Still need to grind this down

These are the stock 250 mounts, i cleaned up and fit to size



Exhaust clearance

I'm missing the bolt on the left because that big blob of weld is in the way, after i get it welded i'm going to remove just enough of that blob to get my bolt in...spring has no problems...




Had to cut this spout off, and used a 1/4'' socket wrench to fit inside the crossover tubes and easily bent them away from the cylinder

Is that motor from your old bike?

ya...my 97 from my other bike...still working on getting another one.

very

looking good bro

Thanks alot guys

I'm having alot of fun doing this build...i must say compares to a gen3 450 this conversion is CAKE! Everything can be accomplished with minimal tools and experience. I've only used a hacksaw and a mini grinder to get everything done so far. I wish i could wake up and do these gen3 conversions every day for a living.

Ok here it is welded up...i'm very happy with my welder on this bike. He proved he knows his shit, they are nice beads and it looks very clean. Not quite stock but it's very close.






Took a trip down to see my buddy Roostius Maximus at his racing engine shop, and he glass blasted my frames and swingarms for me. Next step is polishing em' up.




And since i cleaned up my 450 conversion i figure i'd show some pics of her as well. Here they are spooning each other and looking good.




Though to the untrained eye these frames look incredibly similar, they are actually very different in alot of aspects...by far this gen3 is an easier, cleaner, less expensive conversion. But the 450 chassis for some reason just seems bigger and more suitable to a big boy like myself, and the frame seems somehow 'larger', then the 250 frame. just my 2 cents.

gen3s KICKASS!
very cool dude. MFDB blasted my gen-1 frame and I left it bare, looks bitchen.

I don' know if anyone's noticed, but the 450 frame has a larger more curved frame at the gas tank and shroud area...it sort of feels like a ''fat boy'' compared to a ''roadster''...it sort of seems like the gen 3 450 chassis is the largest aluminum frame chassis for honda, whereas the gen 4 450's frame looks skinnier and doesn't feel as large. Anyways it's too bad it's winter almost cause i would love to ride both these bikes in the next two months it takes to heal my broken ankle and give them a side by side comparison. I guess it will have to wait until next summer.

Thanks for the props Danny, i gotta question about the gen 3 airbox though. Does the stock gen 3 boot line up? or do i have to get a gen 1 boot like i did on my 450 conversion? Just curious because i dont have my bike together right now to check...

My 03 is huge next to most I see, even most 450's Honda's included; most people look at me like I am nuts for even mounting it!! Gotta say tho being a big boy (6'3"-242lbs geared) it fits me very, very well. Since I got the suspension done and added the high bend bars and risers I have been pounding it like a free whore and it responds wonderfully in every way and soaks up everything I have thrown at it!!!!

For you smaller guys I would stick with the 250 builds since they are the better handling chassis.

So you gonna keep the 450 build Bala?

I for sure need to ride them both side by side before i get rid of either one. My 250 isn't finished yet...i've got alot of plans for both of these bikes actually. I love the way the 450 AF feels and looks. I might keep both these bikes actually and make one sreet legal...never know. Alls i know is the gen 3 450 is WAYYYYYY cooler then the 2009 450. I just had a look at one today and i gotta say i'm not impressed...they are actually very ugly. doing a 500 conversion in that chassis will probably never interest me.

oh ya and i wanted to say that my gen3 450 chassis is like a monster compared to the gen4 450...with the 500 in it, it's a massive bike and everyone notices the size.

Check it out...getting started on polishing up the gen 3 frame and swingarm...i almost wish i'd never started because it is one hell of a long process...and a black process as well! i've never been so covered in black in my life. It's not finished, i've only managed to do up to the halfway point on the swingarm with the black compound, and haven't even started with the white stuff yet. But you get the idea, it's gonna be slick as fuuuuukkk.

there is a reason I don't polish stuff... I don't have the patience, then get pissed when it fades.
you might want to put the collars in there to keep the dust out of the bearings

the bearings already took an ass raping when i glass blasted them, even though we took measures to protect them...no biggie. Linkage bearings are also being changed...this is the only frame i'm polishing, fuck this noise. It'll be nice, but if i didn't have a broken leg and nothing but time on my hands i wouldn't be doing this. I predict the frame and swingarm will be finished polishing by late next week if i spend a couple hours a day on it. Jesus christ!

K i know some people think it's a waste of time to polish the AF but i beg to differ...I know it's not gonna last forever but i don't care, it took me probably 7-8 hours, but i still don't care...the pics doesn't do the frame justice, I ended up leaving the lower frame spare area with the blasted finish, i think it's cool having the swingarm polished and just the upper spars polished. it looks siiiiiick...but one's enough...

I'm just giving mine a brushed finish with scotch brite for now. I would like to get it anodized silver, but I think that would cost too much.

It hardly looks like your frame has any wear from the rad shrouds. Mine has a gouge on both sides

the gouge is there, it's just super shiny so you can't see it to well...plus buffing the piss out of it made it disapear a little bit...i like the mirror finish more every time i look at it...

Ok...This is my plug clearance...which is MASSIVE!! Gen3 rules for things like this.

Coil mount...Same location as many other builds i've seen...made a cute little extender piece out of an old 450 mount.

the 500 Bracket doesn't work...which sucks cause i just bought two of them! i can still use one on my other bike though, i lost it somehow on that bike...

This is the 250 bracket...it's tight but it fits and i think looks awesome!

Stock gen3 airboot works perfect without any problems...i know it doesn't look tight because it really is barely on the carb but it DOES fit perfect i was just lazy and didn't wanna dick with it for a pic!

The lowest silencer mount on the gen 3 subframe is usable for the 500 silencer...but i'll need to make another extension piece to fit the upper mount.

Anybody have a good idea what to do with this exhaust mount location?! please let me know if you have any suggestions what to do with it.

Overall view of where i'm at so far...


I still plan on using a pro circuit works pipe and pro circuit 304 silencer for this bike but i still think the gnarly looks pretty gnarly. I'm also wondering about what to do with the cdi box final location...couple location possibilities for it. aaaaand i'm done...that's it for tonight, just waiting on the swingarm bearings and then this pig will be ready very soon, and i can start working on the older AF, and the new 250 i'm going to be putting together for my cousin...ENJOY the pics...

Looks great!

ok here's some billet bling...my brand new headstay (one sided)...





SHWWWING!

Picture day for me so i thought i'd show my new wheels...Got em' for 650$ canadian with tire...the rear needs to be changed but whatever they are mint.



My frame and engine are both finished up the way i want them to be...i can almost picture how the whole bike will turn out from looking at this picture...I just don't know if i want to powdercoat the lower frame spar section where it's blasted finish or leave it, and i have no idea what decal kit or plastics i want on this bike, something to match the wheels obviously, Any and All input will help... This bike is going to be my dream dirt bike...