KX Riders

Maintenance & Technical => KX500 Aluminum Frame Conversion (AFC) => Topic started by: jholt on January 04, 2011, 11:02:45 AM

Title: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 04, 2011, 11:02:45 AM

Just thought I would go ahead and start my Topic to show the progress on my kx500af Build. I will try to keep this updated as I continue with the build. My plan is to have it completed by end of Jan but I am being realistic and End of Feb is probably the more real date. SO Everyone enjoy and if anyone else is doing it and Has questions that I can answer just hit me up...
(http://i135.photobucket.com/albums/q156/holtre1/FathersDay6-20-2010PickwickLake004.jpg)

(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra011.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra010.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra012.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build002.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build001.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build003.jpg)

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 04, 2011, 11:18:06 AM

Wow, your jumping in with both feet.
I'll be lucky if I get mine done by Jan 2012  :lol:

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 04, 2011, 11:29:20 AM

haha  Well I kinda Planned this out I ride the 450 on most weekends so I didn't want to be without my bike while I built this monster.  So I ordered a new frame on Ebay 2008 450 for $250.00. I bought JFAB rails and started from there. I Figured I should be able to just get everything ready and then swap all off the current 450. This should help minimize the down time...

I am currently waiting on my cylinder to come back from Mellinium plating and then I can finish the frame mock up and take to welder. If I was to have this back this week I might possibly be able to completed the mock up this week but we will see. Also as you can see in the other post I ordered the service honda FMF exhaust today, they said I should have it in 3 days this will also help me to make sure that my frame is right before welding...

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 04, 2011, 11:44:35 AM

Good Idea.
I ordered my pipe, arrestor and hoses from them today.
Thanks to all here and AJ at Service Honda  :-D

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: livenlife699 on January 05, 2011, 01:18:13 PM

Looks Like some good Progress!

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 15, 2011, 09:07:51 AM

Finally got my cylinder back and I got the pipe in so we are headed tomorrow to the welder.
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build010.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build009.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build008.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build012.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build011.jpg)

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 15, 2011, 09:43:40 AM

Your passing me up....

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 17, 2011, 02:42:32 PM

Got the first round of welding completed  today just thought I would share

(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build016.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build015.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build025.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build017.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build023.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build022.jpg)

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 17, 2011, 03:09:18 PM

Looks great.
Man your really making quick progress.
I hope mine looks as good  :lol:

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: Spizz on January 17, 2011, 03:11:53 PM

Nice welds.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 17, 2011, 03:25:36 PM

Thanks guys I really appreciate it,  and yes i thought the welder did a great job.  I have to take some credit with the fab work LOL

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: ThrottleJunky on January 17, 2011, 04:44:53 PM

Good looking job! 

I noticed alot of 500AF's and 500SF's cut the frame section out without it bolted in a jig.  Any of you guys compare the wheelbase and rake after the welding is complete? just curious...

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 17, 2011, 04:58:16 PM

Party pooper  :-P

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: ThrottleJunky on January 17, 2011, 06:18:09 PM

sorry!

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 18, 2011, 01:49:28 AM

Due to the factory (I call it the Triangle)  that is not messed with up next to the steering head the rake and wheel base are not affected.  You would have to be really rough with the frame and I mean really rough to affect it any.  The down tube is pretty thick and I am not sure that you can really affect it due to the factory creating the triangle up next to the steering head...

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 19, 2011, 01:14:01 AM

(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build030.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build029.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build028.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build027.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build026.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build031.jpg)

this is just a mock up I have gotten everything mocked up and it will have to go back to welder one final time, I was trying to make sure in these photos I had everything covered and  now I am down to getting the Radiators working and intake boot any suggestions would greatly be appreciated....

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: bempa on January 19, 2011, 07:06:45 AM

Nice work.
See
http://www.kxriders.com/forums/index.php/topic,5511.0.html
for how I did with the radiators and intake boot.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 20, 2011, 01:14:12 AM

Got the Radiator Fixed up and Plumbed Last night. If any one out there is interested get you a YZ 85 Radiator cut the back mount off and this things goes right on. You dont even have to change any of the water necks they are perfect fit. You will have two fill caps or you have it blanked off that is really the only mod.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: livenlife699 on January 20, 2011, 10:56:55 AM

Can you post pics of the yz85 radiators? Im curious on what it looks like...

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: sandblaster on January 20, 2011, 12:33:15 PM

I'd like to see it too.
Thanks!

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 20, 2011, 04:31:39 PM

I will try to get one up tomorrow for you guys.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 21, 2011, 01:11:25 AM

(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build032.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build033.jpg)

here is a couple I took this morning

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: stevea100m on January 21, 2011, 02:51:06 AM

So what are you doing for the right side just staying with the stock radiator?

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 22, 2011, 01:45:20 AM

yea just using stock radiator

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 26, 2011, 12:23:37 AM

well figured I would update it some more, were almost there got to finish the air boot this week and now fix a chain adjuster bolt and she will be ready to go. Here is were I got to last night.
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build041.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build040.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build039.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build038.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build036.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build035.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build034.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2011KX500Build042.jpg)

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: RM_Rider14 on January 26, 2011, 03:50:34 AM

Hot.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: livenlife699 on January 26, 2011, 05:26:57 AM

So what did you do for the airboot set up?

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 26, 2011, 04:25:15 PM

I used a 2002 Cr 250 air boot. I have to say its a little tricky and I will probably fix a couple things on it as time goes on. I saw in one post on this forum were a guy bought a service honda Kx and said that the bolt on the air boot rubbed the shock, and after just getting mine on there I can see were if your not real carefull it can happen I just happened to have some real nice slim head bolts that used and it should be good. But I have say that it clears the shock good and lines up just about perfect.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 27, 2011, 02:04:08 AM

Well it took me right at a month to complete but I got it HERE is the final Product

(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra013.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra014.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra018.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra019.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra017.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra020.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra021.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra022.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra023.jpg)

Thanks for every one looking at my build now we just have to get some decent weather to take it to the track...

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: ID KX500 on January 27, 2011, 02:16:38 AM

Congratulations! Excellent work, I hope it is as satisfiying to ride as it must have been to create.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: livenlife699 on January 27, 2011, 05:13:03 AM

Bike Looks Awesome!!

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: bempa on January 27, 2011, 07:42:31 AM

Congratulations! Really nice.

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: kxpegger on January 27, 2011, 01:01:27 PM

Hammer time!

That was me that had the clearance problem with the air box flange bolt head rubbing against the rear shock oil resevoir on the SH AF. I may buy a new airbox and boot to see if I can eliminate all clearance issues.

Good luck with the monster you created!

Title: Re: Another 2008 Kx 450 to Kx 500af build
Post by: jholt on January 27, 2011, 03:23:59 PM

Thanks Guys I reallly do appreciate it . I am excited to get to ride it. Got to start it for the first time to day man it sounded good.

KXpegger I just used a thin headed bolt on my air box clears the shock great. thanks for posting those issues though cause I probably would not of noticed if I hadnot been looking for it..

again thanks to every one with out this forum and the great info this would of been alot more difficult 

Final Product

(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra026.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra028.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra029.jpg)
(http://i135.photobucket.com/albums/q156/holtre1/2004Cobra027.jpg)