Atc 70 xmas special replica

[oldoo]

Hey all,

Thought I might as well get started on a build thread for my 70.
Basically going for a custom xmas special replica.
So far Ive had the frame stretched 2" and sleeved 4" for strength. I didn't trust myself with this as it is significantly structural, so I got a guru boil maker to TIG it up for me.

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For relocating the fuel tank mounts, I machined down a pin on the lathe at work to the same size as the factory mounts. Then got it welded in and plugged the original tank mounts.
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While the frame was at the boil makers, He drilled and tapped a grease nipple into the rear bearing housing which is handy.

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Fenders Arrived, Will be handy to have them for getting the tank and forks colour coded to match.
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So Basically, only just getting started on the project. But I plan to document the whole build here.

[rip it]

Good luck with your build. I have managed to find a real Christmas special, but the previous owners dog used it as a chew toy. LOL It needs lots of parts that I am slowly trying to pick up. I look forward to following your thread and hopefully getting some ideas along the way.

[oldoo]

Good luck with your build. I have managed to find a real Christmas special, but the previous owners dog used it as a chew toy. LOL It needs lots of parts that I am slowly trying to pick up. I look forward to following your thread and hopefully getting some ideas along the way.

Thanks mate. Yeah I plan to document the whole build here so there will be plenty to come. What is it about dogs and chewing fenders? I have an atc and trx 70 that both have chew marks from dogs lol. I hope you don't cut it up like what I've done. Those things are best left original in my opinion.

[rip it]

I'm going to have to cut up the back fenders, there is too much material missing to make it look right. The front fender I can salvage without too much work. That dog even ate part of the foot peg rubbers and hand grips. LOL What was he thinking?

[HoldMyBeer]

Guru boiler maker huh? So a pipe fitter drop out? That thing is going to be sweet

[oldoo]

Guru boiler maker huh? So a pipe fitter drop out? That thing is going to be sweet

Uh He's #1 welder around man. I also got him to machine my hubs down to fit go kart wheels I'll upload some pics.

[oldoo]

Its been a while since I've done any work on this bike, too busy fixing up my new air cooled 250r. Anyway Here's some photos of the custom rear hubs machined to fit kart wheels.
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I managed to find a set a rear brake hub off an Eton ATV that fits the factory honda splines so I can run a Disc brake setup which will work well. The only thing I will have to do is run a slightly different size seal and machine the crush tube to fit flush with where the hub sits on the axle
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Heres the excess that needs to be machined off because the disc hub is wider than original drum.
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FYI These Eton hubs fit straight onto the atc 70 axle
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Next up is to get the engine and mount oil cooler prior to paint...

[AZ Dean]

I need to go google Christmas Special lol. Have fun with it and keep us posted!

[AZ Dean]

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Sweet!

[oldoo]

So I've finally been doing a little work on the tank getting it ready for paint. I got the dents pulled out now just need to use jb weld to build up and patch where it's been welded. Then off to paint it goes.
https://uploads.tapatalk-cdn.com/20180126/fe30064b04874918a004ee8a2e071359.jpg


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[oldoo]

So the build has had a slight change of course, it's still going to be blue but less of an Xmas special replica...
frame and forks are off for powder tomorrow. Happy to see this project get a move on as I've been tied up overhauling my 250r haha

https://uploads.tapatalk-cdn.com/20180312/145335cd1e68f9c0b7fbb2c8d9a98ccd.jpg

I use heat proof silicon in the surfaces where bearings press into to prevent powder going there. Threads can be re tapped easily enough
https://uploads.tapatalk-cdn.com/20180312/ad9b933bf35d9effdf56e9932e080e1c.jpg


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[oldoo]

So my parts came back from powder on Friday and the reassembly has begun!

https://uploads.tapatalk-cdn.com/20180318/829564edbdf5216da1ee393baa0f67e3.jpg


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[oldoo]

Slowly sorting chipping away at this and my 250r. Engine is dialed in with the new carb -Lifan 125 with 26mm oko flatslide carb (keihin copy). Once my new engine bolts arrive I'll slap it in.
I got the tank painted and it looks immaculate.
There's a bit of mucking around fitting the caliber for the rear disc. If anyone can recommend a caliber that fits nicely let me know. Im trying to make a pitbike one fit...

Yeah my work bench is a bit messy lol

https://uploads.tapatalk-cdn.com/20180409/e0cd71e406fb9874a60b8403549f98f0.jpg

https://uploads.tapatalk-cdn.com/20180409/d2a4c714519f15f22e75393ca56180ef.jpg


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[ivan-083]

Slowly sorting chipping away at this and my 250r. Engine is dialed in with the new carb -Lifan 125 with 26mm oko flatslide carb (keihin copy). Once my new engine bolts arrive I'll slap it in.
I got the tank painted and it looks immaculate.
There's a bit of mucking around fitting the caliber for the rear disc. If anyone can recommend a caliber that fits nicely let me know. Im trying to make a pitbike one fit...

Yeah my work bench is a bit messy lol

https://uploads.tapatalk-cdn.com/20180409/e0cd71e406fb9874a60b8403549f98f0.jpg

https://uploads.tapatalk-cdn.com/20180409/d2a4c714519f15f22e75393ca56180ef.jpg


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Looking sweet buddy! Throw the 250r motor in it ha ha ha


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[big specht]

Want size of e-Ton quad did those hubs come off of? I can't get that part number to come up

[oldoo]

Want size of e-Ton quad did those hubs come off of? I can't get that part number to come up

Hey mate not too sure, I just bought them off a guy who told me that they fit.


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[big specht]

I tried to cross that number on there site and it said the number wasn't any good?

[oldoo]

I tried to cross that number on there site and it said the number wasn't any good?

Hmm strange I'll pm you



Also I've been getting bits plated...
Here's some pics. I got the rear axle crush tubes and front wheel spacers some in matt black chrome. The original triple tree plate came up real good. Just ordered a heap of parts off partzilla so this thing will get a move on hopefully. 🤙🏼🤙🏼
https://uploads.tapatalk-cdn.com/20180604/d68f5815013a4f9b7f31ae1134da1524.jpg



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[oldoo]

Rear wheels arrived today. Picking up the front wheel next Sunday. Then I'll order my Hoosiers.
https://uploads.tapatalk-cdn.com/20180617/0cc8582965649a063e66f934dc309c9b.jpg

I also mocked up some test fitting.
They are American pcd so I'll have to machine down another set of atc 70 hubs at work for them to fit. As my current hubs are metric/euro kart pcd.

https://uploads.tapatalk-cdn.com/20180617/053ddd528f7601cec5daefa7e3d0d927.jpg


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[oldoo]

So I've been busy machining the spacer for the rear disc. I bought some aluminium bar that I faced then bored on the lathe followed by drilling the holes on the mill. All fits nice just need to cut it to length once I've got the caliper mounted.

Caliper is a front caliper off a cr80 '97 that I will be rebuilding. I'm aiming to avoid as much Chinese parts as possible.

https://uploads.tapatalk-cdn.com/20180629/8819a4e4a68aa86cd003a356f3963c4f.jpghttps://uploads.tapatalk-cdn.com/20180629/7eaf36c155ccf7c4c9d177b798c9f91d.jpghttps://uploads.tapatalk-cdn.com/20180629/38a0e6559ffeda6442ebdbc0ef29d721.jpghttps://uploads.tapatalk-cdn.com/20180629/5f3c3167a37a404d24bcd3c276695ba9.jpghttps://uploads.tapatalk-cdn.com/20180629/66c43e4ae208f7c20039e2c4511e1d8b.jpg

I didn't have any long bolts to properly attatch the caliper but it all lines up nicely. I just need to bore the spacer a fraction more to allow the axle crush tube to fit inside. That crush tube will need to be shortened because the hub used is wider than the stock drum.



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[oldoo]

Also engine is in. It's a Lifan 125 for now. Hoping to put a built 4 speed atc 70 engine in it eventually. 126cc bored and stroked kitaco or takegawa kit would be ideal https://uploads.tapatalk-cdn.com/20180629/1d232a55baee635b5b3f840ea7c42d98.jpg


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[oldoo]

So quick update, I got my rear hubs electroplated in matt black plus the axle crush tubes. Front hub and axle spacers are the same. Hopefully I will have a roller within the next week...

Still have to muck around with getting the caliper sorted but I'm off work for a couple months so I won't have access to a lathe unfortunatley. Hopefully the next time I post I will have a roller.

Once that's happened I'll be dropping it off at my buddy's who did the frame stretch so he can make me an exhaust 🤙🏼

From there it should just about be rideable after a little mucking around. Then I'll start my next 70 lol

https://uploads.tapatalk-cdn.com/20180815/81895d5a41d54eec16ea4a4402ac5be0.jpg


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[big specht]

Why such a thick disc spacer?

[oldoo]

Why such a thick disc spacer?

It's going to be approximately half that thickness if not thinner. This was the size of aluminium I was provided. Now I know all the holes are aligned and the right size I will be able to part it off to the correct size once I mount the caliper and have the correct measurement.


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[oldoo]

So my kart rims arrived today and I fitted my tyres then bolted the wheels on. It's looking pretty good. Hopefully I can get my front tyre within the next two weeks.

I'm pretty motivated at the moment so hopefully it stays that way while my 250r resto mod is at a stand still.

Yes I know I need to sort out the carb and tank fitment....

https://uploads.tapatalk-cdn.com/20180816/e934982ad2b943e8d0c1fd461d3d4ebe.jpg

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https://uploads.tapatalk-cdn.com/20180816/1a4c01435881b1944029ff5c419f8652.jpg



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[oldoo]

So quick update, not much has happened but it is now a roller with my Hoosier front Tyre on a douglass 8 inch rim

https://uploads.tapatalk-cdn.com/20181019/a7b25e848adc4bd826d89c4818a9ac11.jpg
https://uploads.tapatalk-cdn.com/20181019/9052d373bc98bf54b776f868572eb7f9.jpg

The custom stand I built for the front end made it nice and easy to fit the wheel.



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[ironchop]

Looking good!

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[big specht]

Yea I like the frt Hoosier what size is it.

[oldoo]

Yea I like the frt Hoosier what size is it.

Cheers mate

15x7-8


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[oldoo]

So I fished polishing the bar mounts tonight and mounted my bars. It’s looking badass yew!
https://uploads.tapatalk-cdn.com/20181026/5e6b4476eb4b4d2b513f02fcfaac50b5.jpghttps://uploads.tapatalk-cdn.com/20181026/7621b177b7fabab0b426117a74c607e9.jpg


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[x-rider]

Looking good dude. Can’t wait to see it finished. I wouldn’t mind scrounging up one of those 70’s!

[oldoo]

Looking good dude. Can’t wait to see it finished. I wouldn’t mind scrounging up one of those 70’s!

Cheers man, it’s getting there.


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[oldoo]

So I started mocking up an adapter plate for the rear caliper. I originally was going to use aluminium but I had steel plate laying around so I’m using steel.

I will be machining some steel pins and welding them to the plate for the bolts to go through. More pics to come as I progress through it.

P.S it’s handy to have a spare frame as seen in the pics.

https://uploads.tapatalk-cdn.com/20181027/32198e87a8c8b16ffb129ed00de7e0f6.jpg

https://uploads.tapatalk-cdn.com/20181027/12151ffd862a4f501bcaa4a4380e1b44.jpg

https://uploads.tapatalk-cdn.com/20181027/343bc023f1cd9284e3be9c5c04fba558.jpg


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[oldoo]

Tonight I fitted my front fender and number plate.
I’m really disappointed with the paint match between the tank and front fender.

I followed advice of the PPG new sears blue and got it mixed up st my local PPG supplier. I’m guessing the guy didn’t mix it well? I don’t know a lot about paint go be honest.

Anyway I cleaned up an original front number plate but I will be upgrading it to an aluminium one that I will be making at some point.

I machined up some spacers to mount the fenders with based off the oem fender washers. I soon found out maier fenders are different so I’ll keep these aside for my next build where I’ll be using some used oem fenders.

Here’s some update pics.
https://uploads.tapatalk-cdn.com/20181102/0412d8d13ca0d58c3dddaa6bdc4df888.jpghttps://uploads.tapatalk-cdn.com/20181102/284a6006ff6b310d25a873244e801b71.jpg


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[oldoo]

Tonight I welded the machined pins for the rear caliper setup. Slowly I’m getting this darn rear caliper mounting sorted.
https://uploads.tapatalk-cdn.com/20181204/612f3ef6fe53ac7689cd913c1f4389be.jpg

https://uploads.tapatalk-cdn.com/20181204/749f2d7e1c57e1a88b9a601d9b2ba586.jpg

https://uploads.tapatalk-cdn.com/20181204/c6648e70a230dcdbf43f9ef94b7dff8e.jpg


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[oldoo]

Still kicking around with mounting this caliper. I either have to grind back the cr80 plate that the caliper bolts to or have to make my own to have enough clearance....

https://uploads.tapatalk-cdn.com/20190108/b205e10342a74218096905e76ebb3eb1.jpg

I have although drilled a few extra holes to secure the plate better to the frame. Long bolts will go through the pins to attach caliper to frame securely.

Hopefully my future builds don’t drag out like this one as I have learnt from this build.

Cheers,
Oldo





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[oldoo]

Alas, disc hub done

https://uploads.tapatalk-cdn.com/20190508/de530de9d10abfe717ade6316ff86104.jpg

Pitbike silencer arrived. Going to shorten it 50mm for better fittment.
https://uploads.tapatalk-cdn.com/20190508/67f6476197139dee2b94970fb6c174e4.jpg

https://uploads.tapatalk-cdn.com/20190508/2350ee4c2a6cf5cfe9a65f932d22785a.jpg

Yoshi Rep lol

Stay tuned, more to come


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[oldoo]

Liking how it looks so far....

https://uploads.tapatalk-cdn.com/20190509/ffca60af6bb087d0d1d1cbdf2cb7dd2f.jpg


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[oldoo]

UPDATE TIME
fenders on, exhaust made,
Just need to fabricate up the intake manifold and a few other small bits.
All in good time. https://uploads.tapatalk-cdn.com/20190828/23c610e88e06ade3bcc7ed06e9e7d0fb.jpghttps://uploads.tapatalk-cdn.com/20190828/2d99c4d92d0531c87fab96448e07e73f.jpghttps://uploads.tapatalk-cdn.com/20190828/a3b7f1b260c1d0d2515d37f761d9dd0f.jpg

Stay tuned 🤙🏼


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[oldoo]

Caliper mounted,

In the process of machine up and welding an intake together.

https://uploads.tapatalk-cdn.com/20191222/087c2f84391bf19c6e053a533c80bdef.jpg

Got the rear sprocket hub vapourblasted.

https://uploads.tapatalk-cdn.com/20191222/6c854ac6ba16d5219658a3e5c3844c69.jpg

Lastly, I’m running a wr450 brake perch up front for the rear brake. I had my mate modify an atc 250r vaster cylinder guard to fit it. I reckon it’s a cool little touch to add to the build.

https://uploads.tapatalk-cdn.com/20191222/390afb21e1b7fcf84e63dff1effb4f09.jpg


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