KXF /KX250

[Reddy]

Clearance for the left hand drop.



I got excited and had to put the tank andplastics back on.

[Reddy]

So the plan for the next week is to get some ali plate and tube to make the engine brackets, exhaust brackets and connect the Y piece down to frame.

Once they are made it can be sent off to be welded!

Does anyone have any ideas on what radiator I can use on the left hand side?  Or is it possible to get one shortened?

[AJ]

reddy,
i only have some old ,*starting the project* shots..
i need to get some of a completed KX250AF up.
I use a 09 KX250 yoke,,,
(similar to what you're using though)
here is the first mock up of the frame..

the radiators - yeah way tougher than the frame..
i ended up modding the lower tanks to clear the raised Y area..
tossed the left rad altogether, and used a right rad on the left side,,
flipped it over, then modified the  tanks..(getting rid of the rad cap spigot) and added new hose barbs accordingly


there's a million different ways to skin a cat though..
you'll get it.

[Dutch-K5 Fan]

Image of Y piece after removing the 2 old engine mount holes

Did you just removed the old the 2 holes??
Or have you weldid a small strip in/on???
I thought it would be hollow.Maybe it could work for me also!!

Good works man.

Dutchie

[Reddy]

Just cut through it with a hacksaw straight through the 2 holes, and then filed and polished the surface, about 20 mins work all in all. Looks good, and gave me the extra bit of room I needed to clear the engine.

Only had an hour on it today, made the 2 bottom engine mounts.

Need to get the ali tube now, think i'm going for inch square with 2mm wall thickness.

[Dutch-K5 Fan]

25x25mm and 2mm thick is stock!!!! Should be good than.
Tomorrow I'll start working again, so I can go further with it.
And give some pics and info again.


Dutch

[Reddy]

Just wondering if you guys bend the ali tube?

Just I need to connect the Y piece down to the original frame and thee is a bend at the end.
Any ideas would be good.

[Dutch-K5 Fan]

I'm planning to make mine own bender. With this as an example.
http://mittlerbros.com/tube_bender_180_hand.htm   
And buy 6 metre alu tube to try


Whow is gone weld your bike??

dutchie

[Reddy]

Thats like th tool i was gonna try and build!
But i dont know how well it will work.

Got a local Ali welder that races local to me, so he's gonna do it all

[Dutch-K5 Fan]

Welllllllllllllll.................To be honest I didn't found that link, is't JFAB's
But hat more or less the same idea, only wasn't sure if it could work.
I think to go to a old famely friend(JBR SERVICE) for the welds.
When you see al of those 500's over here. Don't you whant it also than???
Or is that the next step???

dutch

[Reddy]

Sorry about the delay guys! But my bike is now ready to be welded (pics uploaded soon)

I;ve done a fair bit of work, but it now looks like a bike again.

I've bought a set of Honda CR250 radiators, as I cant find anyone to shorten my KXF rads, and to have a set made was gonna cost me ?380! So i'm hoping the honda rads will fit with a mounting bracket.

Once I get it back, it can be stripped, greased/cleaned/polished and then assembled!

Just hoping to get something sorted with the airbox and radiator hoses now 

[Reddy]

At las tonight i am having my frame welded! Its been a long time coming, mainly been waiting the the ali welder!

Once its done will post some pics of the bike, and take loads of pics as I build it up for the last time

[Reddy]

Its not quite finished, only a few hours left though.

[Reddy]

OK so I finished my bike on Sunday afternoon and raced on on the Monday! First time racing a 250 2 stroke and I loved it.
Here are some pics

[Danger4u2]

Very good write up, pictures on the mark, quality build. A+.  Nothing like a bike built with your own hands.  Does it count that I bolted all the aftermarket stuff on the bike AJ built for me?