Author Topic: My Budget Desert/Play Bike build (Read 16105 times)

troybilt · « **on:** October 21, 2013, 01:48:57 PM »

Starting another 250r build, just for fun. Its going to be low cost/budget oriented build that is based off of my 89 stock bike. I got sick of my stock bike and it wasn't selling, so I'm going to do a bolt on build with as much stuff of my own as possible. I had a few parts left over from the part out of Elsinore so I'm installed those.

So here is where it is today: Stock 89 motor that I plan to run a resleeve stock cylinder 295cc motor setup for XC or torque. Fullbore full fender fronts, ungusseted unmolested frame, Still working on a plan for shocks those will come later.

I reverse engineered some airboxes for White Chassis, which were for Laeger and Walsh hybrids, but I had the original prototype that I welded up and decided to see how it fit in a stock 250r. Fits like a glove, I used an ESR center mount billet mount to hold it on the front and used an 07 YFZ boot, almost like it was designed for this bike. Worked out much better than expected. The airbox fits my YZ hybrid perfectly so I wasn't expecting it to fit the 250r this well.

As you can see I modified my Elsinore pipe silencer and it fits up nicely. It has a sweet sound but still rather quiet when its taming 250cc and not 500cc LOL!

Over the weekend, (since this is on a budget) I needed some aarms so I cut up some stock 88/89 aarms and fabbed up some +2.5 wide, +0.5 forward aarms, that turned out pretty good for my first set. I used the ball joints and the tube ends from the stock aarms then fabbed up the rest. These use stock length shocks of course.

Well I keep posted stuff as I build it, so far I have 0 Dollars into this except for the bike itself.

Pumashine · « **Reply #1 on:** October 21, 2013, 02:17:20 PM »

Did you use a jig to fix the tube ends at the correct distance to fit the frame?

troybilt · « **Reply #2 on:** October 21, 2013, 03:06:35 PM »

I sure did, I made a fixture from the stock aarms before I cut them.

jcs003 · « **Reply #3 on:** October 21, 2013, 03:39:37 PM »

looks like a cool build. cant wait too see more.

john

Hawaiiysr · « **Reply #4 on:** October 21, 2013, 08:04:34 PM »

I see your going to do a stock resleeve 295cc. Will this from LED? In his forum he mentioned that he would offer the same build he did for Bill balance for $1000 until February.

Pumashine · « **Reply #5 on:** October 21, 2013, 08:34:38 PM »

Looks great Troy. Did you make all the bends in-house? I mentioned the jig because welding tends to shrink the over all dimensions.

rsss396 · « **Reply #6 on:** October 21, 2013, 08:40:55 PM »

Nice! even better Troy has not given up on the 250R I thought maybe we lost him to 4 pokes

fearlessfred · « **Reply #7 on:** October 21, 2013, 09:58:40 PM »

arms look great .we used to do the same thing back in the early 90s before you could just buy long aarms. glad to see you back in action

atv fan 28 · « **Reply #8 on:** October 21, 2013, 10:59:00 PM »

Troy always has the nicest build threads!!

jamieg45 · « **Reply #9 on:** October 21, 2013, 11:06:16 PM »

Nice work Troy and the those full fronts look great on there too man.

etccb · « **Reply #10 on:** October 22, 2013, 10:12:21 AM »

Aarms look great, nice work.

troybilt · « **Reply #11 on:** October 22, 2013, 10:22:51 AM »

A-arms installed for test fit-up. They are made from 1" 0.095 Str Tubing. Not chromoly, cause I didn't have any in my shop. My other sets will be fabbed/welded by Jerry and use chromoly, these are just for fun.

Here is a picture of my bender: (bent these all myself)

Here is a pic of TIG/MIG combo, GO LINCOLN!! LOL!

As far as the cylinder, Dan gave me a 72mm bore OEM re-sleeve cylinder, I just need to hone it a little and find a cool head to match and Wossner or Namura piston kit. I want to run as much compression as possible, 240+ psi.

Fearlessfred, when you going to let me give your desert sled a proper restoration? LOL! I thought maybe you guys tried this back in the late 80's-90's. These turned out better than I expected. I'm totally happy with the uppers cause I didn't have a 3/4 die for my bender so I had to sleeve 1" over the top to extend them vs. rebuilding the aarms... but these are just for my play bike so not a huge deal, they work.

troybilt · « **Reply #12 on:** October 22, 2013, 10:25:50 AM »

I still need to make some longer tie rods, and longer brake lines. The tie rods are not hooked up right now, they are just zip tied to the uppers.

I will get everything coated once I'm done, next I'm going to attempt a full tubular swingarm.

jamieg45 · « **Reply #13 on:** October 22, 2013, 12:03:22 PM »

Great work man, so what did you find out about the problem I had bud.

troybilt · « **Reply #14 on:** October 22, 2013, 01:39:06 PM »

Jamie, they said it was not possible to shift or be off, if the cut file is correct. I rechecked the cut file, had Jay at FWC check it for me as well and that all appeared right. I also printed my own set (see on my hybrid thread), I found similar issues with the template: For instance the graphics hung down about .5 to 1" on the right side kicker area, but I just trimmed that extra material off, the kicker area didn't line up that great, but I played with it for awhile and got looking OK. I didn't have the same issues as you on the upper right down the nose area, I was able to get that to line up decently. I could see how one could get off cause its tricky there. Probably not what you wanted to hear, but that's all I got for you. thanks for the compliments.