Maintenance & Technical > KX500 Aluminum Frame Conversion (AFC)

2006 KX250F / KX500 my son rightly named "The Juggernaut"

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royceymon@hotmail.co.uk:
know what you mean about the upkeep ,did the same on my kxf swing arm , kickstart and  hgs pipe , looks the nuts though  i used our workshop 415v ind bench grinder with mop wheel and ali soap ,your right you do need to get the heat into it!! nice tip on the black marks in the weld!!ta

sylvester:
No much going on lately... side plastic showed up though.

Before



After

taffymoto:
looking sweet mate...cant wait to start mine :-D

livenlife699:
The Frame all polished up looks awesome!! The bike should look great when its done, How did you bend those frame rails? They came out really good! Im trying to figure out how to bend some myself for my new build

sylvester:
I just copied the factory bend and transfered that to a 2x10, cut the profile on the band saw ( you can see the block in the 3 picture) just out of the picture at the top there is a 2x4 on the oppisite side of the tube for leverage. Learn from my mistakes get a 6 foot piece of 6061 aluminum square tube cut it in half then do the bends. If you don't get enough leverage to perform the bend you will only hurt yourself, trim to length AFTER the bending process. Now the trick, sweat the aluminum. I warmed it up with a propane torch, just enough to ease the bending process and to keep the metal from cracking or bunching up. For the sharp bend, I just stuck it in the vise with aluminum padded jaws ( you dont want galvanic corrosion). Just remember... WARM not HOT, and a little heat is fine, too hot will ruin the strength...especially if it is heated repeatedly.

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