350X 400EX Transplant Build!

[Matt85'350x]

Here are the rest of the mounts I made. The 2 rear ones I cut out, ground them to shape, re-designed the drawing, and recut them. All of the mounts are 5mm thick stainless steel. Way overkill compared to the OEM plates but I don't mind.
By the way if for some reason someone wants the drawings for these mounts, I'd be willing to share them.

[Matt85'350x]

I didn't use any of the original 350x spacers. The lengths aren't right and they don't lend themselves to be modified nicely since they're not a uniform width throughout. What does work well are the 400ex spacers. My measurements are as follows:
-front: 2 x 4.5mm
-bottom: 2 x 42mm
-top: all you need is an M10 washer on each side
-rear: 1 x 79.5mm. This is if you use 5mm thick material (which if you do you don't need a spacer for the connecting side of the engine)

[Matt85'350x]

I purchased all new hardware for mounting the engine from mcmaster. I didn't opt to go stainless, I went with steel like the original bolts were. Because of the thickness of the plates the only bolts I could have reused would be the ones for the bottom and the rear.

[oscarmayer]

awesome job sir!!!!!!
you should make notes and sell spacers and plates as a kit for like $125 for people to do bolt on conversions.

[Louis Mielke]

very impressive build!

[Matt85'350x]

very impressive build!

Thanks. I thoroughly enjoyed your 400 build, did you ever get it running?

[Dirtcrasher]

I believe you've done a great job!! Regardless of opinions, it's built well and you'll be able to see how well it works in your opinion.

I love the laser cut mounts, well done sir!!

While it's apart, put some gussets on the frame; Even the 350 motor needs them and you've got it apart.

[Matt85'350x]

I believe you've done a great job!! Regardless of opinions, it's built well and you'll be able to see how well it works in your opinion.

I love the laser cut mounts, well done sir!!

While it's apart, put some gussets on the frame; Even the 350 motor needs them and you've got it apart.

Thanks for the compliment. My plan is to send my frame to HRE to gusset and relocate my shock mount. I plan on running their swing arm which will allow me to run the 450r shock, carrier, and axle. Need to sort everything else out first though-he's going to powder coat my frame so there's no frame mods after I send it in.

So for the oil tank I've weighed all my options and I've got some different opinions than I did originally. A lot of good ideas came out of this thread and I did heavily consider all of them. The frame just couldn't hold enough oil and would have been inconvenient for checking and draining oil. Putting a tank in between the swing arm and the engine would hold less than the stock tank-I just can't come to grips with that; I've got too much time and effort invested already to end up with an engine that could be prone to overheating.

For me making a tank to go behind where the air box is now is the best solution. The dimensions will be a 5x7" rectangle that will fit in between the frame rails. One mount will go where the rear of the air box mounts now and 2 more mounts will be made for the front. Tank will be made out of aluminum and mounted with rubber isolators. I've ordered the raw materials from mcmaster and the bungs from http://www.bungking.com/. Should get the parts this weekend and hopefully have something to show next week.

For the air box I'll make a custom box out aluminum. It won't have a lid, so more of a tray I guess. I'm not going to be going through any rivers with this so this'll be just fine.

That's the plan for now-pics and progress reports to come next week.

[Matt85'350x]

As promised here's my progress on the oil tank. Bought a 5x5 inch tube and some fittings online. Went with aluminum over steel because the tube I found was cheaper than the steel and the fittings weren't much more. The tubing is 1/8 inch thick. Between the frame rails there's about 7 inches of clearance. So in buying a 12 inch piece of tube and accounting for the wall thickness there is enough material to make a box out of just the 12 inch piece. Then all that's needed is to cut to length, cut the side pieces out, and drill the holes for the fittings. I decided that all of the lines would come from the bottom so the return is going to have an internal tube up to the top. Instead of a vent line I opted to use a vented cap.

As far as mounting I'm using the rear air box screw for one point and I will make 2 tabs to mount the front.

I'm waiting on the rest of the fittings and I've also got to make the tabs. After that happens I'll get this thing welded up. Hopefully it'll be done next week.

Please let me know if these pics came through. This is my first time trying tapatalk.

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[Matt85'350x]

Ok let's try the pics again.













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[BOB MARLIN]

Looks like your well on your way to solving the oil tank problem, good job. Are you going to put the battery in the same area ?. I have one 350x with a goki and I put the battery where the goki kit recommends to, witch is really in the same spot as the EX. Most people don't like it there and put the battery in the air box but I wanted to keep the air box the way it was. I have had zero problems with the location, like I said ,it works for the EX and its just fine for the 350x.
A friend of mine bought one of the new lithium batteries for his EX. They are amazing. They weigh almost nothing-really. When I first picked it up I thought it was just an empty case, kinda like a display at the store, they only weigh ounces not pounds, and they are a little more compact also. I think it would be a great option for a project like yours.

[RIDE-RED 250r]

I agree with Bob. I owned a 400ex a couple of years back and found that the battery location seemed as though it would be problematic. But despite what it seemed, I never had an issue with it.

I like the route you are taking with the oil tank. Looks like you will have plenty of capacity and the tank should be well protected and out of the way there.

[Matt85'350x]

Thanks for the compliments! The oil tank idea came from everyone's suggestions. I can't wait to get it welded up but have to wait for more fittings. The picture on the website had 3 fittings on it so for some reason I thought the price was for a 3 pack. Sorely disappointed when only 1 came!

I had a Polaris predator that had the same location as the 400ex for the battery. It was never a problem and was convenient if I had to jump it. That's probably where it'll end up going but I am planning in a lithium in an attempt to still keep the tool box.

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[Matt85'350x]

Got my tank welded up. He did a great job!











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[Matt85'350x]

Here's where it'll mount. Rear using the air box screw. The angle bracket will be used for the front. Monday I'm going to laser cut a cross member for the frame which is what the front of the tank will mount to. I'll drill the holes after the cross member is installed.










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