Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
'09 500AF build
jBernard:
--- Quote from: Kraemer864 on December 01, 2014, 05:15:34 AM ---Wow! Awesome build! Im currently building a 2012 kx250afc with a 04 kx250 motor. Im looking for someone that makes yokes and a headstay mount. How much would it cost if you were to build that yoke for me? Also what angle did you bend the frame rails to? I have the tubing to make the frame rails but I dont know what angle to bend them to. Thanks!
--- End quote ---
here's a couple pics of the rear headstay i got machined up
i just drilled 2 M8 sized thru holes spaced to try and get as much triangulationt as possible. then welded on. it welded surprisingly nicely to the cast frame cross brace.
im going to waterjet a couple pieces of thick (around .250) carbon fiber plate to connect the headstay to the head. should be a nice change from the usual aluminum and steel, and will actually help any vibration from getting transferred.
Kraemer864:
Great headstay design! Do you still have a headstay for sale?
jc5057:
Dang that is going to be one nice bike
jBernard:
Long overdue update...
Been struggling to find someone to turn a handfull of one off Titanium fasteners for me, but finally found someone and shouldn't be but a week until I get a decent amount of parts back that have been holding me up. Then linkage should be 100% done with a few tricks up my sleeve as well for it.
But some good news is that I've had some AWESOME people lend a helping hand on my project. I've made some good new friends in the industry and I'm honored that they enjoy looking at my build and like to contribute. These are stand up companies, who care about US riders and not trying to screw people out of their money and just sell as much as they can.
PLEASE help support these people if you ever need any of these products. I've talked to a lot of people regarding my project and these are the guys that love the sport.
SWEET new throttle from G2 Ergonomics, with a 400 cam to try and tame some of the 500 hit. The cool thing about this throttle is that you can easily change cams for desired throttle response.
The fit and finish is awesome as well.
http://www.g2ergo.com/
Kevin @ Tamer Holeshot Devices helped me out with this awesome holeshot device in a gorgeous finish anodizing.
Kevin is a super nice guy, that rode for Honda back in the day. He INVENTED the holeshot device, yes, holds the patent for it. In my opinion his is the coolest looking one of everyone that is basing off his design.
http://www.tamerbilletmx.com/
Josh @ Racetech Titanium is helping out tons. I really have dreamed of having some trick Ti parts on my bike that were just a bit over my head to fabricate, and he was able to make that dream a reality. I've turned Ti before and it is no joke. The finish and precision on his parts is unreal. Top quality company! He supplies all the Ti parts for the JGR team, how cool is that!
http://racetechtitanium.com/
6AL4V Ti Front/Rear axle + Pivot with DLC Coating
- DLC Coated Ti Linkage bolts (awesome!)
- KXF Kickstarter bolt
- Banjo bolt + bleed screws
- Brembo DLC Coated Slider Pins Front + Rear
- Brembo DLC Coated Pad Slider Pins
Finally got headstay bracket back from the laser cutter and it turned out OK.
The headstay is .125 which is WAY overkill but what the heck. Only issue is that you have to cut Ti with Nitrogen shielding. And its not easy to cut, even compared to cold rolled steel.
There is a bit of drift in the cut from the top to the bottom, I will have to go back and ream out the thru holes to make sure they are nice and square. I dont know if this is a laser wattage issue, or just something that happens cutting thick Ti plate, as I've never cut something this thick. Waterjet would probably have been a better option, albeit more costly by far.
With all the extra room I decided to layout a few more Ti pieces while I could. KIPS front cover plates in .125 and .80 Plate, and swingarm spacer tabs (no more rust!)
Got sick and tired of looking at that hideous yellow spring on my shock.
This looks a bit better now :-D Powdercoated anthracite grey.
Also can see in this photo I'll be adding a Brembo rear master cylinder and caliper to replace the Nissin stuff. The master cylinder mounting tabs don't fit up, so an adapter will have to be made.
Front headstay tab that will be welded onto the frame will be back within a week, then I'll weld that on and fit it, then send frame off the heat treat, and engine off the get put back together at Tom Morgan Racing. Hopefully lots of progress made in the next few weeks.
Thanks for looking and hope everyone is liking what I'm coming up with
Taylor
Foxx4Beaver:
very nice progress as usual!....
I've been thinking about picking up one of the G2 tubes too, I've been waiting to see if anyone has any feedback on them before buying one, as my Pro Circuit throttle tube has been around the block for several years, and it's about time to retire it.
And since I've been planning on buying a new rear axle...I may just look into the RT ti.
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