Project Clean Out the Closet - aka the Frankenbike

[umberto]

I have a lot of parts left over from my aluminum frame conversion, including a frame, swingarm, 2004 250 suspension redone by Enzo with the triple clamps, plastic, airbox, and seats.  With bike prices high and supply low, I figured I might be able to replace the things I am missing and make a little money on selling what I have.  I went to eBay and ran some numbers, and I think I can achieve the dual goal of getting a little cash and a little space at the same time.  Today I put together what I had with the wheels, tires, axles and spacers I bought off of eBay.  I was missing a few items I stole for the aluminum bike, but I was lucky that I had extras from other projects.  I attached a picture of where I got today.  I think it will be a nice looking bike once done, and I can feel better about keeping a 2004 in the dirt for a while longer.

The motor comes in tomorrow, and the rest of the pieces should be arriving throughout the week.  I'll keep you posted on my progress.

[Pmcg]

Looks great.  I am jealous of the lift!

[umberto]

Looks great.  I am jealous of the lift!

Thank you Pmcg. I felt bad letting that frame sit when it could be a bike someone could enjoy. Plus it gives me something to tinker on. 

The lift is from Harbor Freight.  They have it on sale pretty often, if you’re signed up for their e-mails. I’ve had mine for nearly ten years, and have never regretted buying it.

[umberto]

I got the motor in today.  It's a 1997 model, but it was complete and a really good deal.  I wasn't sure about what years used similar cases, but it bolted right in and the carb lined up with the airbox boot.  I think it will need a replating and a piston, but it came dirt cheap so I'm okay. 

It did have one very "interesting" modification.  Some previous owner had broken the clutch cable holder on the case, so they rigged up a replacement.  It used a small wrench that was trimmed to fit the broken profile of the cable holder.  Not very pretty to say the least.  It swiftly was taken off and thrown in the trash.  I'm also not sure why someone removed all the paint from the ignition cover and put "V-TWIN" on it, but that will get a freshening up as well.

[umberto]

I bought a 2003 head so I can use the factory head stay, and I will match it with a 2003 piston.  I also got the front brake in today.  It's from a KXF, but it bolted up with no issues. 

Most of my other factory stuff will be in on Wednesday, so I should be able to get this dude mocked up before I blow it apart and start painting, detailing, and motor rebuilding.

[Pmcg]

That's a redneck repair even by my standards.  How many PBR's do you think it took to fab that?

[umberto]

That's a redneck repair even by my standards.  How many PBR's do you think it took to fab that?

I’d imagine it was several.   

[umberto]

I got a ton of parts in today, and almost completed the mock up phase.  I replaced a bad head stud and installed the 2003 cylinder head and stay.  Thankfully it bolted right on, and now the motor is fully mounted.  I then added new GPI radiators and stock hoses.  I was pleasantly surprised at how well the radiators mounted.  I am going to have to enlarge the holes to fit the louvers, but everything else lines up nicely.  Not bad for $76 with free UPS shipping.  I also added the used FMF Fatty and Powercore 2 silencer.  I found a complete 2004 rear brake and got that installed, along with new sprockets and an o-ring chain. 

The front end got folding green aluminum levers and a new brake clamp for the fork guide.   I previously added a Motion Pro throttle assembly, so all I need is a set of grips and I am done with the controls. 

The CDI box should be here on Saturday, and then the mock up is done.  Then it's on the the engine and detailing.

[umberto]

I got the CDI in yesterday, but unfortunately there was no spark.  It looks like the coil is the culprit, so I ordered a new one from Sandblaster.  Today I figured I would test the bore to see if it is worn out or not, and then finish the mock up before I tear the motor down for a rebuild.  The bore was worn, which I kind of figured, so it's off to Millennium Technologies on Monday.  With that figured out, I continued on to the last mock up items.  I made a few small adjustments to the radiators so the louvers would fit, made new brackets for the shrouds with rivnuts, added the throttle cable, and finally started working on the clutch cable.  The previous owner of the motor had a few PBRs and fixed the broken mount with an old wrench.  I figured I could do a little bit better, so I came up with a 16 gauge metal bracket that I welded an insert on to.  Once it is painted, I think it will look really nice and it will be a ton stronger than the drunk wrench. 

Once I was done with the clutch holder, I went ahead and assembled the whole bike with graphics to see what it would look like.  I think it will be a really nice looking bike when I am done.  Now it's on to the motor.

[Pmcg]

looking good.  Big improvement on the clutch cable holder!!

[umberto]

looking good.  Big improvement on the clutch cable holder!!

Thank you Pmcg.  I was pretty happy with how the bike turned out.  It's all back in pieces now, but at least I got to see what it would look like together.

The clutch holder went a lot better than I thought it would.  I even eyeballed the mounting holes and got them right the first time.  I should have bought a lottery ticket that night.   

[umberto]

I sent my cylinder to Millennium Technologies, and they measured it as being a little bit out of spec.  Luckily the cylinder had been sleeved, but not yet bored.  They were able to clean it up with an overbore and get me a Wossner piston that fit.  I got an e-mail today that it was done and ready to ship out.  That was all I was missing to get the bike back together, so hopefully I'll have some progress pictures after the weekend.

[mjowen]

gorgeous bike, man

[umberto]

gorgeous bike, man

Thank you mjowen, I'm really pleased with how it turned out.  Hopefully someone will want to take it home in a couple of weeks.

[Pmcg]

I love it when new parts show up.  I would be waiting for the UPS guy at the curb when he showed up.