Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)
How well do you like your KX250F/K5 conversion
sandblaster:
Bye bye Donor bike :-o
It's being disassembled as I write :-D
Nooooooooooooooo!!!!!!!!!!!!!!
Please, someone stop me......
Too late :-D
sandblaster:
12-30-10
I went ahead and purchased some brand new engine cases for my engine build.
This left me with a nice set of blanks for my Mock Up Engine.
Installed a back up cylinder and head .
Now, it's time for a big drill....
sandblaster:
Now you see it.....
Now you don't.....
I used my Sawsall with a fine metal cutting blade.
Then, after I removed the mount I used a hand grinder and then a orbital sander to smooth it out.
I know it's not necessary as nobody will see it.
Yet for some reason I will feel better :lol:
sandblaster:
Today I received my Mock up engine back from the machine shop I had drill my 17MM swing arm bolt hole.
As a side note, I bolted the case halves together with a factory gasket.
I had the machine shop set the cases on the clutch side with the clutch cover off on a set of parallel blocks and then drilled it to maintain perpendicularity.
Drilling was very easy.
Before I tried to fit the engine I did a test fit with the swing arm bolt.
I had to use a rubber mallet and hit it hard to get the dadnabit thing in.
So, I wire wheeled the pin and de-burred the hole.
It was still too tight.
I grabbed my digital veneer calipers and see that the holes through the frame are 17.05MM.
I guess they were allowing for manufacturing tolerances.
Also, I put a straight edge on my pin and it was nice and straight.
Since I do not have a ream of the correct size I went to the local auto parts store and picked up a wheel cylinder ream.
After about 15 minutes of oiling and reaming it finally fits snug but can be put in by hand.
So, the results for today are as shown below:
If I was going to order another drill, I would not use the 17mm.
I would use a 43/64" as it is 0.672" or 17.06 mm.
This is only .01mm or 0.0004" larger than the holes in the frame.
Now that I see how it fits, it's time to cut some more on the frame.
I better order some frame rails soon.....
sandblaster:
11-5-11
Old carriage goes to the recyclers...
Not really, keep all the pieces, you never can tell when one will come in handy :-)
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Now.... it is too late :-D
I am also keeping track of cost and the offset of selling the left overs.
I will post all info when it is done. (Gulp)
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