'09 500AF build

[jBernard]

thanks!
having the guys that precision ground the Ti clutch pushrod to do the grinding on these as well, then my buddy will part and thread the ends. i'm not going to make the cylinder studs waisted like the stockers are.
i'm going to TRY and broach the ends with a hex head so i dont have to double-nut install them. but that may be hard to do with the quantity i have and be to much $$$.

[RoostiusMaximus]

I use these....http://www.vehicleservicepros.com/product/10106652/goodson-tools-and-supplies-stud-removal-and-installation-tools

[jBernard]

long overdue update!

have some awesome new people helping with the project, their parts finally came in, so time to give them some recognition.

Ken @ ARC Levers is an oldschool Open class rider and really appreciates my build. The composite levers they offer are amazing, highest quality pieces.
After seeing these my friend called Ken up and got a set for his '14 KTM 250SX and LOVES them. I contemplated going with the ASV levers for a while, but these are a far better product, better price, and the guys at ARC are always trying to help the riders.

Ken accidentally sent me the RC-8 mechanical clutch kit for my bike (very confusing to tell people you have a 1990 KX500 engine in a new AF KXF chassis, that uses a Brembo Hydraulic Clutch) haha!
I almost want to go back to mechanical now! The whole perch, pivot, and lever combo was INSANE! It's a work of art! Sadly sent it back but mine is just as high of quality!

http://www.arclevers.com/





One thing that's been concerning me a bit is how rigid my Yoke is, and how beefy the motor mounts are, but there's a lack of strength between the two for about 3" on the downtubes.
Thought about trying to weld on some alum strips on the inside, but that wouldn't look as nice.
So ended up modeling up some easy pieces to 'extend' down the tubes between the bottom of the yoke and the bottom of the top motor mounts. this should add a lot of aluminum thickness to this area and take my mind off of any kind of stress fractures arising.





Have some updated parts a friend helped me get made to share as well, just some blurry phone pics for now, but once they come in this week I'll get some better ones for everyone.

The stock D Bolt that comes with the Applied triple clamps (bolt that goes thru the bottom bar clamp and mounts it to the top triple) Is a heavy ass 3" long M10 zinc coated steel bolt.
We can do better than that can't we?




Rekluse Clutch spacer is DONE! Left a lot of stock on it for precise fit and hopefully as much chain clearance as I can get.



Teaser of the Mg Linkage shot. those Ti bushings are for this, then I can press in the bearings and it will be DONE finally! Eager to see how much my design weighs compared to the stock. I think it will be a lot.


Inconel 718 stock for cylinder and head studs is FINALLY done being precision ground. Now comes parting and threading each piece.
This stuff is crazy hard, pretty much a nightmare to turn down, so grinding is usually the way to go on this material. Makes Titanium seem like butter, and the only thing I've cut more difficult than it was Stellite 6.



Next steps:
- Weld front headstay bracket on frame
- Mill engine case to fit Rekluse Clutch Spacer
- Weld on lower yoke braces
- Assemble engine!

[dave916]

Very tasty work
U should start making a few of them bits for sale,that  clutch hyd spacer would be a handy sell and easy to post 

[jBernard]

Couple of update photos to show finally.

peg bracket assembly finally done.
Racetech Titanium again hooked me up with some Ti peg bolts (fat shorty M12's) and M8's. dished head, just real nice stuff as usual.



Now peg assembly is done. Ti everything, Bolts, Brackets, Custom Pins, Raptor Ti Pegs. looks TRICK!




Here are the lower yoke braces I posted a picture of in the last post from Solidworks. I've held them up so you can see the fitment, I matched the width of the Yoke, and used same radius, so I can just fill that in, grind the joint down, and it will look like a longer yoke, but way more strength.





Headstay front bracket weld-in piece is in, I've taped the Ti uprights and the alum spacer together to show fitment. Of course, there will be 2 M8 bolts going thru it all (holes already in alum piece)




Rekluse Clutch spacer fits crazy tight, looks great.
I'll drill the 3 holes after it's welded to the case, I'm a bit worried about heat distortion on the threads if I do it pre-weld.




Everything except bearings in the linkage is either Ti or Mg



And a cometic gasket kit for upper and lower.




Hopefully getting frame and case to machine shop and welder here within a week to get the rekluse completed as well as the frame rail braces and weld in front headstay mount

Stay tuned!

Crazy the amount of response this is getting, over 18 THOUSAND page hits!
I feel bad for not getting more accomplished sometimes but there's so much on the plate it's staggering. But I think the time and effort to be meticulous is going to pay off with a one off result in the end.

[umberto]

I love this thread JBernard!  It's one of the main things I always check when I come to the site.  I don't mind that you don't update the build daily, because when you do update it's always something really trick.  Keep up the good work, I can't wait to see the finished product!

[jBernard]

Hey all.
Sorry for the lack of updates. Super tied up with work, but have gotten a few things done on the KX and a few parts bought. Making some more progress this week as well.

Inconel 718 Cylinder studs and 2 sized head studs done finally.








HPSD Mount made, still need to hardcoat anodize this piece black.






Linkage all together. All Ti and Mg!




D-Bolts for Applied trees out of Ti



Still working on the brake fitment adapter for the Brembo Calipers! Getting closer



TM Designworks came thru with some help on a super nice Endurance slider and roller kit for my bike.
They are super cool people and have some nice products with awesome fitment!
http://www.tmdesignworks.com/




Lightspeed carbon fiber chain block and Cycra new plastic guide.


Got a nice new set of plastics on the bike, went with the acerbis flo-green kit off a '15 450. everything fits right up except for top bolt mount on shrouds, and the thru holes on front fender are a bit to large, the bolt pattern is fine, just have to make some collars for the M6 bolts.




Thought about getting a PWK online and slapping it on this bike and then having to mess with dialing jetting in for who knows how long. Thought I'd continue supporting awesome companies that care about its buyers instead.
I've been in contact with Kevin at Lectron Fuel Systems about putting a Lectron on this bike. We settled on a 40mm Power Jet being the best option for me.
Check this thing out. Billet bowl, 40mm.




Ended up going with a PowerDynamo stator and flywheel + a reg. Didn't want to struggle with power lacking while running onboard data acquisition and the electric water pump and KIPS servo motor.
Super nice craftsmanship on this part, very impressed. I also went with the lightweight flywheel version. Will have to see if it makes the bike to much of a rocketship.




Finally nailed down an electric water pump that should work for my application.
LOTS of searching produced this. Looks like it will hit required #'s with ease, and is made by Bosch so hopefully no failures. Also its about as light as can be for the size. 12V also, so will play nice with power system.




Stay tuned for some more updates! Hopefully will have the hydraulic clutch mod done to the case tomorrow, latest this week if something comes up. Then engine off to TMR.
Thanks for checking this thread out, crazy its over 22K views. That's a lot!

Taylor

[SS109]

Ended up going with a PowerDynamo stator and flywheel + a reg. Didn't want to struggle with power lacking while running onboard data acquisition and the electric water pump and KIPS servo motor.
Super nice craftsmanship on this part, very impressed. I also went with the lightweight flywheel version. Will have to see if it makes the bike to much of a rocketship.

Wow, what a build! I am in awe and a lot jealous. That stator is amazing. Thanks for showing it as it is what I have been looking for to work with my build.

[dave916]

MY God wish i had pride in my work like this

U will need a controler unit for that water pump?

http://www.bdkraceeng.co.uk/Electric%20Water%20Pump%201.html

[sandblaster]

Beautiful.... Simply amazing...
I wonder what the final weigh in will be?

[umberto]

This build never ceases to amaze me!  Such amazing fabrication and innovation.  It's like watching Chip Foose build hot rods. Only problem is that it makes my builds look like amateur hour.    

[alward25]

Beautiful.... Simply amazing...
I wonder what the final weigh in will be?

I would guess the same as a KX 500 in stock trim.  The AF frame is about 7lbs heavier and with all the gram shedding it will be pretty close to th 220-225lb I would guess.  I know the flywheel is almost half the weight   Looking awesome.  Setting the bar pretty high for the rest of us..... d**n him.

[RoostiusMaximus]

does the seat line up with using that body work?

[jBernard]

Thanks for the nice words guys. Helps me keep motivated and at this thing!

I was able to get down to use a bridgeport earlier today, chopped off the side of the case to fit the Rekluse hyd. unit.

A buddy is going to help make a little adapter so everything will be perfectly centered, then I can take it to get welded

Hopefully it will clear with a 14T sprocket. but its going to be REAL close. I'm using about the most beefy chain made, a DID ERV3, this thing looks like it's off of a forklift! So the 14T and the super wide/tall chain isn't going to help my clearance issues.
If I go down to a 13T front, its going to increase wear on my chain guides, how much I dont know though.

[jBernard]

does the seat line up with using that body work?

I forgot to order the airbox covers with the kit. so i dont know if the '15 airbox covers are that much different. But the rear plates and the rear fender fit up fine to the older subframe surprisingly.
The shrouds fit everything but the top mount bolt. that design is different of how it overlaps the tank. But i've got a few tricks i'll do to make that part end up working.