AlisoBob's Gen 4 A/F Conversion

britincali · Post by **britincali** » December 5th, 2008, 7:54 pm

Post by **AlisoBob** » December 5th, 2008, 11:12 pm

sabreguy wrote:
AlisoBob wrote:16,000 + view's......

Yea but 15,000 of those are you looking at them

That still leaves 1000 more than look at your bike....

aloha450x · Post by **aloha450x** » December 6th, 2008, 12:39 am

here is my lack of build. 61,000 views http://www.supermotojunkie.com/showthread.php?t=48380

aloha450x · Post by **aloha450x** » December 6th, 2008, 12:40 am

here is my lack of build. 61,000 views http://www.supermotojunkie.com/showthread.php?t=48380

sabreguy · Post by **sabreguy** » December 6th, 2008, 11:13 am

AlisoBob wrote:
sabreguy wrote:
AlisoBob wrote:16,000 + view's......

Yea but 15,000 of those are you looking at them

That still leaves 1000 more than look at your bike....

well the other 1,000 are me going "Damn I should've bought that bike"

and my bike is a "classic"

juddy · Post by **juddy** » December 6th, 2008, 7:13 pm

did you guys grind out the little airbox bolt nipple things on the boot side? it looks like bob did, i decided to drill holes to make the lexan fit right tight against the box...but after i did that i realized that it would probably be better to grind them off and have a complete sheet covering all the holes...

I drilled those little studs out and am going to use 6mm countersunk head bolts to bolt the existing airbox setup to a lexan type material adaptor plate.Hopefully by the end of the week I will be near completion and will get some pics of all these pain in the ass bits and pieces that are involved with the gen 4 CRF 450.

Post by **AlisoBob** » December 6th, 2008, 7:20 pm

juddy wrote:did you guys grind out the little airbox bolt nipple things on the boot side? it looks like bob did

I drilled them out, but in reality they spun, heated the pastic, and pushed out.

The plastic kinda " self healed" ..then cooled.

It worked out pretty bitchin'!!

lewisclan · Post by **lewisclan** » December 6th, 2008, 7:22 pm

over 16, thousand hits

Post by **AlisoBob** » December 6th, 2008, 7:25 pm

This is how it all pieced back together...

Balaclava · Post by **Balaclava** » December 6th, 2008, 7:43 pm

juddy wrote:did you guys grind out the little airbox bolt nipple things on the boot side? it looks like bob did, i decided to drill holes to make the lexan fit right tight against the box...but after i did that i realized that it would probably be better to grind them off and have a complete sheet covering all the holes...

I cut and grinded the lexan to fit over and between whatever piece of airbox was protruding. As you can see i just filled it with some killer black silicon where the airbox nipples are and it's air tight.

Post by **AlisoBob** » December 6th, 2008, 8:27 pm

Post by **AlisoBob** » January 20th, 2009, 8:47 am

lewisclan wrote:over 16, thousand hits

18.5

oggo69 · Post by **oggo69** » January 20th, 2009, 1:42 pm

23 pages later , more evil eyes from my wife to be .... credit were credit is due , excellent thread and work bob , very inspiring , in fact all AF build threads are , cant wait to start mine , frame should be with me next week , but the motor will be next month

oggo
was i viewer 18501 ... do i win a prize

Post by **AlisoBob** » January 20th, 2009, 2:10 pm

Mine was basically built like Honda did it...

Look at TTM, Chachi's, Mik, and other builders work for really clean, custom stuff....

oggo69 · Post by **oggo69** » January 20th, 2009, 2:25 pm

AlisoBob wrote:Mine was basically built like Honda did it...

Look at TTM, Chachi's, Mik, and other builders work for really clean, custom stuff....

i deffo will,, seen some teem's stuff and i like the idea of the machined y piece , i used to doing machining for years and i dont have access to a cnc anymore ..... BUT my one of pals does

gona do some more homework over the next couple of weeks ..

TrxR · Post by **TrxR** » June 5th, 2009, 5:11 pm

AlisoBob from what I understand is you just cut the y section at the welds top and bottom?? How much did you cut off the downpipe to move the Y up and what thickness tube did you use for the 1 inch stuff? Also am I seeing things wrong or does the 500 motor use the same lower motor mounts?
Thanks

Sorry for bringing back such an old thread.

Post by **AlisoBob** » June 5th, 2009, 5:33 pm

TrxR wrote:AlisoBob from what I understand is you just cut the y section at the welds top and bottom?? How much did you cut off the downpipe to move the Y up and what thickness tube did you use for the 1 inch stuff? Also am I seeing things wrong or does the 500 motor use the same lower motor mounts?
Thanks

Sorry for bringing back such an old thread.

No problem.... I check this thread every 20, 508 views....

1. The "Y"... Yes is the stock "Y", just moved up. How much you cut off depends on how thw motor is "clocked".. Mine is pretty straight up and down to me able to use the stock 500 pipe "As- Is". This requires the "Y" to be higher. Rolling the motor over more, requires the "Y" to be a little lower... Ever bike will be slightly different. The stopping point is when the Rad hit the "Y"... you dont want to lift the "Y" any higher than that.

2. The aluminum is .125" thick , radiused corner aluminum.

3. The lower tabs are fabbed from 1/4" flat stock... nothin' special.

Man, I love this bike!!!

TrxR · Post by **TrxR** » June 5th, 2009, 5:45 pm

Is there any advantages or disadvantages about rolling the motor down or up any? Also is anyone making mounts or head stays to make it easier to position the motor in the right spot? So the stock Y doesnt require any mods other than removing the stubs and placing where needed?

Thanks

Post by **AlisoBob** » June 5th, 2009, 5:46 pm

TrxR wrote: So the stock Y doesnt require any mods other than removing the stubs and placing where needed?

Thats the WHOLE conversion , right there....

TrxR · Post by **TrxR** » June 5th, 2009, 5:57 pm

Thanks it looks quite straight forward and simple actually. My other small question is what year is classified as the gen 4 like yours? And how about gas tanks will a larger capacity desert tank work ?

dannygraves · Post by **dannygraves** » June 5th, 2009, 6:38 pm

um, all of these questions are all over this board, you should check out some of the other conversions too. On both of the ones I did I clocked the motor as far forward as possible and was very pleased with the additional gas tank space and boot angle. but you have to notch the frame very deep for the clutch cover bolt boss to clear.
my conversions aren;t in the completed thread, I think Bob was too embarased of my nigyvering to put any of mine in that thread

honestly, the frame is the easy part with a gen-4, the tank, airboot, exhaust, rad hoses, etc. are the tough part.
also, Bobs is an X, if you use an R you need to use a gen-1 250 or 125 boot.

gen-4 is '04+ crf250R and X or '05-'09 crf450 rand X

honda02 · Post by **honda02** » June 9th, 2009, 7:23 pm

Check out this link this is how I did my airbox on my 450.

http://cr500riders.com/cgi/yabb/YaBB.pl ... 4335/45#45

dannygraves wrote:um, all of these questions are all over this board, you should check out some of the other conversions too. On both of the ones I did I clocked the motor as far forward as possible and was very pleased with the additional gas tank space and boot angle. but you have to notch the frame very deep for the clutch cover bolt boss to clear.
my conversions aren;t in the completed thread, I think Bob was too embarased of my nigyvering to put any of mine in that thread

honestly, the frame is the easy part with a gen-4, the tank, airboot, exhaust, rad hoses, etc. are the tough part.
also, Bobs is an X, if you use an R you need to use a gen-1 250 or 125 boot.

gen-4 is '04+ crf250R and X or '05-'09 crf450 rand X

yota · Post by **yota** » June 10th, 2009, 1:59 pm

yo Bob, I just found this thread for the 1st time, read all 24 pgs, nice job man. how are you liking the crf250X suspension?

CR500R7 · Post by **CR500R7** » June 15th, 2009, 6:53 am

Since someone revived this thread I reread the whole thing again, thats a mighty good build for sure Bob.
Congrats,

BannedCR500Riders.com

AlisoBob's Gen 4 A/F Conversion

Airbox