Gen 3 swap, 2002 cr250 swap.... Pic Heavy

Hillbilly500 · Post by **Hillbilly500** » February 27th, 2010, 4:14 pm

UPDATE>>> All done, Took 12 days from Buying 250 to finished..

Ok, Going to do it.. Bought a low hrs 2002 cr250r(keep it green stickered here in ca) today and am using my 96 500 motor and such(roller for sale).. Plan to copy a build I saw on cr500riders. more than likely here too since it looks so clean. I will try to take lots of pics

Algava's Build
http://cr500riders.com/cgi/yabb/YaBB.pl ... 12913934/0

http://www.bannedcr500riders.com/board/ ... php?t=4874

Here are the Doners

caseyracing222 · Post by **caseyracing222** » February 27th, 2010, 4:33 pm

IMO The only thing that looks good on that build is the welds. I would seriously question the strength of the cradle. If your not going to replace the entire cradle (aussie style) then I would lean more towards Bobs method, It looks stronger... just my

12voltguy · Post by **12voltguy** » February 27th, 2010, 4:33 pm

get it billy!
now delivere my 4 fitty

asteroid500 · Post by **asteroid500** » February 27th, 2010, 6:35 pm

Yep Bobs looks to be stronger to me to.

Hillbilly500 · Post by **Hillbilly500** » February 27th, 2010, 7:10 pm

give me a link to Bobs method if you could.. Got the bike torn down to bare frame this after noon

Hillbilly500 · Post by **Hillbilly500** » February 27th, 2010, 7:32 pm

is this the one your referring too?

http://www.bannedcr500riders.com/board/ ... 89&start=0

Kinda hesitant to to bend aluminum vs a quality Tig weld, Every time I have tried bending aluminum it gets fatigued.. hmm Well at least you have me thinking now, thanks for the input

Hillbilly500 · Post by **Hillbilly500** » February 27th, 2010, 8:41 pm

thanks for the info Bob.. Good talking to you

After talking to Bob it really looks like it is hit or miss depending on each frame if it is a good way to go.. I will mock up the motor in the next week and see what looks best.. But not scared of a properly welded splice in the frame. Keep you guys posted

Mik329 · Post by **Mik329** » March 1st, 2010, 7:06 am

look in the completed bikes thread here for some Gen 3 ideas

Hillbilly500 · Post by **Hillbilly500** » March 1st, 2010, 7:10 am

Yea, Spent good part of the weekend doing just that.. some nice stuff out there. I still think I am going to do it just like the original idea.. I don't see it being weak at all. More than likely going to start cutting this evening or tomorrow

Got alot of good info from Bob too so feel pretty confident on this swap.. Hopefully have some updates by tuesday night

Post by **AlisoBob** » March 1st, 2010, 7:18 am

Hillbilly500 wrote:
Got alot of good info from Bob too so feel pretty confident on this swap.. Hopefully have some updates by tuesday night

Were all here to help, if you get lost....

Hillbilly500 · Post by **Hillbilly500** » March 1st, 2010, 7:20 am

Liking this Forum alot already, thanks

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 6:33 pm

Got started today on the frame mod, I have to admit the first cut was a tough one

Any ways it is going really well, I used my porta band and sawzall. And to clean up things a file was a big help. Below are the steps I took today

First cut, Kinda nice took the weld flush off with the frame

Second I cut the lower radiator mounts off to make it easier to cut welds flush with frame, this ends up being awesome since when I weld the mounts back on i will kick the radiators out on the bottom slightly to make more room for the Y moving up

ground off rivot for wiring harness, dont know if I will need it again

Second frame weld cut

12voltguy · Post by **12voltguy** » March 2nd, 2010, 6:35 pm

ooooooooo nooooooooooooooo

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 6:39 pm

Cut off the lower coil mount so I could get blade in to the inside frame weld, need it flush, I marked their location and angle too.

Marked the lower tubes for cutting, about 1.5" from lower mount hole center, cut is being made 90* square with tube

About 5/8" higher already

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 6:43 pm

Idea of gap needed

radiator in place to check clearance, cutting off the lower mount will be a plus plus kinda thing here, when I weld them back on it will help kick them out just a hair to clear higher Y

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 6:49 pm

Here is a shot with of the outlets< the line is where I am going to cut a pie shape piece out to bring the tubes in some to clear the cylinder

just another mock up shot of radiators and location, nothing final yet

look how thin this stuff is

Post by **AlisoBob** » March 2nd, 2010, 6:49 pm

Shit... your almost done!

Post by **AlisoBob** » March 2nd, 2010, 6:51 pm

Hillbilly500 wrote:look how thin this stuff is

Thats why having a good welder is so important.

Kinda makes all that billet stuff look overkill, huh?

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 6:53 pm

Another couple shot of the frame and Y , still need to cut mounts of Y. will do that tomorrow, anyone have a jig I can borrow? I'll pay shipping.. trying to keep my doner 500 bike together as long as possible

And excuse my messy shop:D

Post by **AlisoBob** » March 2nd, 2010, 6:59 pm

Hillbilly500 wrote:I am going to cut a pie shape piece out to bring the tubes in some to clear the cylinder

You can take a large cotter pin, a piece of emery cloth... and make a small "flapper wheel" to clean out any boogers on the inside of the weld area when your done with the modifications...

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 7:01 pm

AlisoBob wrote:
Hillbilly500 wrote:I am going to cut a pie shape piece out to bring the tubes in some to clear the cylinder

You can take a large cotter pin, a piece of emery cloth... and make a small "flapper wheel" to clean out any boogers on the inside of the weld area when your done with the modifications...

good tip, I will do just that, Hey you want to lone or rent me a jig for a week or so? I know you have one.. I would buy one but he told me he is out of the country for a couple weeks

HrcRacing · Post by **HrcRacing** » March 2nd, 2010, 7:10 pm

Man, it's hard to believe how thin that Y is.

The conversion is lookin' good though.

12voltguy · Post by **12voltguy** » March 2nd, 2010, 7:22 pm

keep your 500 in one piece
we need to go ride in 2 weeks
if it drys up a little

Hillbilly500 · Post by **Hillbilly500** » March 2nd, 2010, 7:25 pm

I plan on riding this one in less than 2 weeks

Algava · Post by **Algava** » March 2nd, 2010, 9:31 pm

Hi, looks great, you sure aren't waisting any time on this build.
The Y was pushed up just enough to clear the pipe (remember you need enough to hook up the exaust springs and the manifold bolts) but make sure the radiator bottom have enough clearance.
5/8's sounds about right but it's not critical.
Keep up the good work.
I have about 80-100 hrs on this bike.
30-40 of them are at Motocross tracks and the rest is desert riding.
My bike is not exactly a museum piece, it's dirty and the pipe all banged up.I have lost a few bolts here and there but no stractural damage yet.
I and MIKEZEROFEAR built another one he recently sold for $4500, and are doing a gen4 as we speak(I'm making the frame inserts, engine mounts and headstay).
I also have copied the build from other people, and I 'm pretty sure there must be quite a few gen3 built this way.
If the welds are done properly the Y will hold ...it's the stock one.

BannedCR500Riders.com

Gen 3 swap, 2002 cr250 swap.... Pic Heavy

Gen 3 swap, 2002 cr250 swap.... Pic Heavy