Dutch 500AF Conversion 250KXF 2009

[jBernard]

i too am going to try to get a cone pipe built. what material are you going to try to use? I've got a good laser cutter source and would like to use 6al4v Ti but still trying to find someone that can weld it without being over the top $$$. do you have the software or a sheet roller yet?
good ideas youve got, me and you think alike.

[Dutch-K5 Fan]

What about Stainless steel for the exhaust?
Jos, do you know how much KX500AF's are there in holland?


Dutchie

[Jos197AF]

Stainless steel, 0.8 mm.

I've no idea how many KX500 AF conversions The Netherlands counts. Never seen one KX5AF before here, much more CR500AF's.
Do you have a picture of your AF Dutch?

[Dutch-K5 Fan]

I think I'll do stainless later this year, mine is rusty now.
Also have a SPES lowboy that I want to copy in stainless.
The pic's
https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#
And there are many more of other AF, SF, Jadoul and more.

Build thread
http://www.kxriders.com/forums/index.php/topic,4891.0.html

Never seen a kx500AF than mine. I have her for 5 years now, and still loving it.
Have you ever ridden a 500 befor?
And where you from? I live in Rijsenhout(Schiphol).

Dutchie

[Jos197AF]

I think I'll do stainless later this year, mine is rusty now.
Also have a SPES lowboy that I want to copy in stainless.
The pic's
https://picasaweb.google.com/102067261144953476086/BuildOfA07KX500AF#
And there are many more of other AF, SF, Jadoul and more.

Build thread
http://www.kxriders.com/forums/index.php/topic,4891.0.html

Never seen a kx500AF than mine. I have her for 5 years now, and still loving it.
Have you ever ridden a 500 befor?
And where you from? I live in Rijsenhout(Schiphol).

Dutchie

Very nice!

Never rode a KX500 before, but I've had a Honda CR500 for 5 years:




Ik kom uit Brabant.

[mxaniac]

So I know I'm sounding like a broken record here (what is the modern phrase for that?) so I'll bring this up one more time and shut up about it.  You really  need to take a second look at 7075 on the frame.  I've had field failures with product using 7075 because of the smallest surface scratches from machining which promoted SCC.  This has nothing to do with welding, machined parts in 7075 can fail under pretty benign conditions.  7075 needs to be in the T7 temper for this application but you might very well anneal the rest of the frame too much by doing so.  You need to look at the aging curves of all the alloys involved and see if a compatible process exists.  If you don't you could end up in the hospitol or under ground.

[Jos197AF]

So I know I'm sounding like a broken record here (what is the modern phrase for that?) so I'll bring this up one more time and shut up about it.  You really  need to take a second look at 7075 on the frame.  I've had field failures with product using 7075 because of the smallest surface scratches from machining which promoted SCC.  This has nothing to do with welding, machined parts in 7075 can fail under pretty benign conditions.  7075 needs to be in the T7 temper for this application but you might very well anneal the rest of the frame too much by doing so.  You need to look at the aging curves of all the alloys involved and see if a compatible process exists.  If you don't you could end up in the hospitol or under ground.

Thank you for the advise. The welding of the 7075 y part went striking great in my opinion. Above my expectations, honestly (no visible heatcracking by the welding proces). I know the risk before choosing this alloy. I made the construction secure, the weld can crack, but the Y part can't get a way out of his position. Or the orginal chassis has to crack completely under the Y part. 
My English isn't that good to explain it at its best to you. The bike won't take huge jumps (the tracks i ride in the Netherlands don't allow that. My talent don't allow to take big jumps also ).

I will supervise this issue frequently! If I see any failure, if I suspect any upcoming failure, I can easily replace the 7075 part for another aluminium alloy Y part.

The welding went great by my feeling and by my welding experience, and the welds looks good also.


I am very cautious at this point. We shall see after charging the beast 

[motopunk]

http://www.motor-forum.nl/forum/list_messages/367415/Kawasaki-KX500AF-Conversion-1.html

Here she is Motopunk

Dutchie

thanks dutchie...  and i´ve seen elsnorro was also there..    

.. jos, your cr500 looks also not bad, but you will not miss it, after first kx500 ride...  
... in the last years i tested nearly all big bore 2strokes except the most aircooled models... 83 suzuki rm 465 in 1979 twinshock-frame, 95 maico 500 , 98 kawasaki kx500, stock 99 honda cr500 and a 98 cr500 ex-gp-bike from german sarholz-honda-team that a friend of me owned for 2 years, 92 ktm mx500, 95 ktm sx440, 97 ktm sxs 360, 99 ktm sx 380, my kx360 engine in 93,97 and87 frame and my 93 conversion with the 86 kx500 motor ...my result: the kx500 is the best big bore engine ever made. smooth, but powerful with big amount of over-rev when needed..  in direct comparing the cr500 is an aggressive tractor with a short rpm-range ...only useful for handful of riders that are able to handle this rocket-effect that the stock-engine produce ... i could, but my heart is green now..    

[Jos197AF]

http://www.motor-forum.nl/forum/list_messages/367415/Kawasaki-KX500AF-Conversion-1.html

Here she is Motopunk

Dutchie

thanks dutchie...  and i´ve seen elsnorro was also there..    

.. jos, your cr500 looks also not bad, but you will not miss it, after first kx500 ride...  
... in the last years i tested nearly all big bore 2strokes except the most aircooled models... 83 suzuki rm 465 in 1979 twinshock-frame, 95 maico 500 , 98 kawasaki kx500, stock 99 honda cr500 and a 98 cr500 ex-gp-bike from german sarholz-honda-team that a friend of me owned for 2 years, 92 ktm mx500, 95 ktm sx440, 97 ktm sxs 360, 99 ktm sx 380, my kx360 engine in 93,97 and87 frame and my 93 conversion with the 86 kx500 motor ...my result: the kx500 is the best big bore engine ever made. smooth, but powerful with big amount of over-rev when needed..  in direct comparing the cr500 is an aggressive tractor with a short rpm-range ...only useful for handful of riders that are able to handle this rocket-effect that the stock-engine produce ... i could, but my heart is green now..    

ElSnorro...... I am making a steely KX500 conversion for him!

[Dutch-K5 Fan]

Have seen some guys on marktplaats(Dutch ebay) made an AF and never ridden a 500.
What happens next, they sell it because it's to fast. ( It is offcourse, don't tell them   )

Have been riding with the KNMV Juniors for 7or 8 years in the south district.
So have been 40km around Eindhoven alot. Couple of trainingcamps at Veldhoven. I used to be a real sand rider but for the last 5 years it's mostly hardpack, a place were the KX500AF works verry well I must say.
The funnist thing some one said to me who raced with me at the 125 class was.
MAN that REALLY hurts riding behint you with that roost!

Motopunk, That are alot of CC's in your riding live


Dutchie

[Jos197AF]

Have seen some guys on marktplaats(Dutch ebay) made an AF and never ridden a 500.
What happens next, they sell it because it's to fast. ( It is offcourse, don't tell them   )

Have been riding with the KNMV Juniors for 7or 8 years in the south district.
So have been 40km around Eindhoven alot. Couple of trainingcamps at Veldhoven. I used to be a real sand rider but for the last 5 years it's mostly hardpack, a place were the KX500AF works verry well I must say.
The funnist thing some one said to me who raced with me at the 125 class was.
MAN that REALLY hurts riding behint you with that roost!

Motopunk, That are alot of CC's in your riding live


Dutchie

Veldhoven.....that tricky track brought me some injuries......:

[kxpegger]

Have seen some guys on marktplaats(Dutch ebay) made an AF and never ridden a 500.
What happens next, they sell it because it's to fast. ( It is offcourse, don't tell them   )

Have been riding with the KNMV Juniors for 7or 8 years in the south district.
So have been 40km around Eindhoven alot. Couple of trainingcamps at Veldhoven. I used to be a real sand rider but for the last 5 years it's mostly hardpack, a place were the KX500AF works verry well I must say.
The funnist thing some one said to me who raced with me at the 125 class was.
MAN that REALLY hurts riding behint you with that roost!

Motopunk, That are alot of CC's in your riding live


Dutchie

Veldhoven.....that tricky track brought me some injuries......:

Ouuch! Great job on the AF! Some real precision work going on there! Kawasaki should be taking notes!

[sandblaster]

Too bad there wasn't a metallic tape or other process that could be applied to the outside of the frame rail that would discolor when the rails were under extreme tension.

[motopunk]

Have seen some guys on marktplaats(Dutch ebay) made an AF and never ridden a 500.
What happens next, they sell it because it's to fast. ( It is offcourse, don't tell them   )

Have been riding with the KNMV Juniors for 7or 8 years in the south district.
So have been 40km around Eindhoven alot. Couple of trainingcamps at Veldhoven. I used to be a real sand rider but for the last 5 years it's mostly hardpack, a place were the KX500AF works verry well I must say.
The funnist thing some one said to me who raced with me at the 125 class was.
MAN that REALLY hurts riding behint you with that roost!

Motopunk, That are alot of CC's in your riding live


Dutchie

dutchie ... and i doesnt listed my 50cc simson , the 3 125´s and the 7 250´s that i owned over the years. .. i was interested for myself , how much diferent the big bikes perform, before i buy or make myself one...  since last last spring, i ride my first own kx500..and it is lot of fun to see the stunning guys on the track, that afraid of 250 2strokes and cant believe that a 500 would be rideable    ..


@jos... did not know, that you are the mastermind of elsnorro´s sf-conversion as i gave him a little bit help to fix his carb-holder-problem... 
by the way... you make great work with your project...

[Jos197AF]

Have seen some guys on marktplaats(Dutch ebay) made an AF and never ridden a 500.
What happens next, they sell it because it's to fast. ( It is offcourse, don't tell them   )

Have been riding with the KNMV Juniors for 7or 8 years in the south district.
So have been 40km around Eindhoven alot. Couple of trainingcamps at Veldhoven. I used to be a real sand rider but for the last 5 years it's mostly hardpack, a place were the KX500AF works verry well I must say.
The funnist thing some one said to me who raced with me at the 125 class was.
MAN that REALLY hurts riding behint you with that roost!

Motopunk, That are alot of CC's in your riding live


Dutchie

dutchie ... and i doesnt listed my 50cc simson , the 3 125´s and the 7 250´s that i owned over the years. .. i was interested for myself , how much diferent the big bikes perform, before i buy or make myself one...  since last last spring, i ride my first own kx500..and it is lot of fun to see the stunning guys on the track, that afraid of 250 2strokes and cant believe that a 500 would be rideable    ..


@jos... did not know, that you are the mastermind of elsnorro´s sf-conversion as i gave him a little bit help to fix his carb-holder-problem... 
by the way... you make great work with your project...

Thanks!