Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
1990 KX 500 to 2006 KX450F Conversion Project
cmotodad:
Here is the hose from AutoZone. Been working great on my SFC 500. I went to the local auto zone and found hose #A71415, crossed that number to Gates. Gates hose was $ 10.99. It is the exact fit of the SH hose.
umberto:
--- Quote from: Kwackerman on February 19, 2015, 03:42:17 AM ---Don, Charlie, and JBenard, you guys aren't offending me in the least. I expected something much more "factory-like" for $1000, from someone who's been doing this for years, but at this point it is what it is. At least the bike is all fitting back together well, with the exception of the pipe.
As for the welds, the local guy I took my bike to to finish the fabrication and fix the pipe, does AF conversions too and has hand built about 30 custom cars from scratch over the past 30 years. I went to him first to do my project, but he was too busy and I was in a hurry. It NEVER pays to get in a hurry!!! Anyway, he looked at the welds and thought they looked OK, but agreed with some of the comments on here that he wouldn't have gone the route George did with the down tubes. He said he would have bent brand new tubes and installed them (as stated by others on here), instead of piecemealing the tubes together.
His ccraftmanship is nothing short of amazing (like the pics at that link). He built two KDX220/KX250F hybrids for a father-son team I race with, and their bikes truly look better than factory. And he did each bike for about $1,100.00, including final assembly. All they had to do was pick them up, fire them up, and go racing. You can't beat that!
I'm picking my bike up from him today after work and I'll put some more pictures on here of the completed pipe, airbox, and radiator mods he did for me.
I just hope my frame doesn't break. I'm a racer and that could be really ugly!!! You can bet I'll be inspecting that frame very closely after every ride for a while.
I'll keep this thread going and post a race report after my first hare scrambles, 1 March.
--- End quote ---
Do you have any contact info for the guy that's helping you finish your bike? Sounds like he might be a good source to join the forum and post some pictures. He might pick up some work too.
scooterVOOII:
Just a thought Kwackerman, but think about this. Book a slot with your friend for next winter, ride your bike this year. If you like it, have him redo it. As long as the frame holds together, just run it. If you don't like the bike, don't proceed. I'm doing the same thing with my bike, Adam Millar is redoing my motor mounts, and doing up a proper head stay for it. I paid Fanelli a Grand to make a mess of mine, I'm paying a second time to have it fixed. Lesson learned, life goes on.
Kwackerman:
Guys, the local guy here (Camdenton, MO) is Steve Bonaker. I'll ask him tonight if he minds me listing his phone number and email on here. Like I said, he does amazing work and his prices are very reasonable. He's also been racing off-road bikes for years, so he gets where we're all coming from.
I appreciate all the encouragement. My bottom line is that I hope after all the expense and work that my hybrid works better than my original K5. I've had several guys ask me why I went away from the chromoly frame to the aluminum frame for woods racing, because the chromoly frame has more flex than aluminum. I told them it's just something I've always wanted to do. If I don't like it, I may do something crazy like pull the motor, sell the chasis and try a KTM hybrid. I've seen some Youtube videos of those and they look really cool too. we'll see.
I just like to tinker...
umberto:
I think the modern suspension and ergonomics should make up for any additional harshness in the frame, especially if you have your suspension valved to your weight and riding style. If you were coming from a later model steel framed bike, it might be more of a glaring difference. Plus it's so unique you'll be a rock star where ever you ride it. 8-)
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