After seeing sandpuppies 600x and watching Jason's 450 from behind all the time, I came to the conclusion that I need more power! I came across a killer deal on a xr500. It came with the frame, swinger, mono shock, forks, airbox, carbs, plastics, triple tree, gas tank, seat and the motor. I want to try and incorparate as much as I can of the xr parts. I started off using the frame because of the oil reservoir and moved on to the rear swinger. The only parts that I had that might handle the horsepower was a '85 350x swinger and axle. I ended up extending it 3 inches and fabing up a mounting point for the rear mono. I wanted to use the xr500 rear suspension because of the heavier motor and heavier self ( no comments please, my wife cooks to good,) and also the fact that it has the famous honda pro link set up. When I was thinking about the rear frame, I wanted to give it some extra clearance because of the longer travel in the suspenion and the larger 450 muffler that I will be using. I welded the tubes on a bit of an angle to achieve this instead of running them straight like the 350x. I'm going to give the rear part of the frame a little more thought. I'll probably extend the rear plate a bit more and add mounting tabs for a grab bar.
I had to extend the inner tube of the '86 350x triple tree to except the longer neck of the xr500 frame. I had to die grind out the bottom neck of the 500 and put in a 200x bearing race so I could use the 350x bottom race with the xr500 top bearing.
I wasn't quiet sure what kind of foot pegs I was going to mount. I thought about using the 250sx pegs, but change my mind at the last minute and decided to go with the 350x. This way I could use the mounting points as a gusset as well. I thought the same thing with welding in a heavy gusset to hold the gas tank and rear fender. After I welded them solid I started to think about the air box and tubes. I wish I would have thought about them eariler because today I cut them out,I know now how I'm going to mount them. I'm going to go with a custom air box. I think I'm going to run an open top and buy a car filter to use as a lid. I'm not 100% sure yet, I have to go to a parts store to see what's the smallest filter I can get.
I'm still a long way to be finished, but I'm in no hurry. I still have to find some parts for the xr. The motor threw a chain and damage the cases. I have replacement center cases, but I'm having problems finding the left case ( alternator case) If you have one or know of someone that wants to sell one, please let me know, thanks.
I'll post progress reports as I go with the build. Any suggestion will be greatly appreciated.
The pictures are just to give me an idea of what it will look like. I'm think I'm going to purchase a plastic gas tank and be done with the rust! I'll probably buy new plastic, but that's not for awhile
Tapper
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Originally Posted by AJZ_200X
