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Thread: Barnboy's 1984 ATC200M Rebuild

  1. #61
    Join Date
    May 2006
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    The Open Road
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    4,729
    Motor looks fantastic

    So does that NASA axle.... WOW

    Sucks about the frame. I'm hoping you can save it

  2. #62
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Quote Originally Posted by ATC King View Post


    I mostly say that for people wanting to flip these things, but in your case...wowzers, good luck with that one. I'll definitely appreciate seeing what your solution is.

    I understand the amount of work that goes into something like that.



    Keeping the foot peg area clean is a real PITA though. It's a big muck trap. I'm surprise more of them aren't rusted out in that area.
    Yeah I totally understand. And honestly....I think you are correct, I was just talking a lil smack. But I'm gonna give this a go. However I'm open to the fact that it may not be fixable. For example if we cut into it and its rotten way further than we thought, and so much would have to be cut out that its new frame time. Whether that be custom or a solid OEM. If I had the resources I would be building a custom full suspension frame, cause that would be badazz. But I'd like to at least attempt to repair this one. Whats the worst I can do? Screw it up worse??

    You are absolutely correct re: keeping the footpeg cavity clean. I would wager that if everyone that owned a hardtail that was taken through mud etc often checked that area, 75% would have rust. At least. I will likely drill some larger drain holes in the tube, and also some drain holes in the footpeg mounting crossmember. Also will be going around and welding places like the end of the flattened frame tubes, where water can get in. Plus, instead if the paper-thin tube honda used, ill be replacing the rusted section with 1" OD DOM. Likely .109 or .125 wall....but .125 wall may be too thick. We shall see.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  3. #63
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Quote Originally Posted by ironchop View Post
    Motor looks fantastic

    So does that NASA axle.... WOW

    Sucks about the frame. I'm hoping you can save it
    Thanks Chop, appreciate it. That NASA axle was def a cool piece to score. Beats a used replated OEM axle all to pieces.

    Will keep this thread updated with pics of progress on the frame.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  4. #64
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Aaaaaaand we are moving forward. Parts cut on the plaz today. Need to get some tube and then start makin sparks!!

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  5. #65
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Update!!! Stuffs been happening on the build, some good some bad. Let's start with the good. Frame subsection is fabbed up and welded out! Looks good as new and definitely more heavy duty, which is perfect I used 1" OD 0.125" wall DOM tubing, bent on the JD2 bender. I also turned 2 plugs to fit inside the old frame tube and the new stock, to keep things lined up. Then the whole thing was TIG welded, my first time ever TIG welding carbon, prior to this I've touched a TIG torch maybe 2x really, just on some aluminum here and there.

    I also drilled some 5/16" drain holes in the bottom of the frame tube, along with 2 new holes on the bottom of the footpeg mount/dirt collector.

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    Note the 2 extra holes
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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  6. #66
    Join Date
    Jul 2010
    Location
    Arkansas
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    2,196
    The Six Million Dollar Trike




    You sir, have got to be in the top tier of hardtail frame savers. Right tools, right experience, right on time.
    The story of three wheels and a man...

  7. #67
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Oklahoma
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    Quote Originally Posted by ATC King View Post
    The Six Million Dollar Trike




    You sir, have got to be in the top tier of hardtail frame savers. Right tools, right experience, right on time.
    Yeah no kidding. Haha, I'm going to have 10x into it what its worth, but thats ok with me. Its never gonna be sold.

    Thanks King, its honestly just access to the right tools and at the right time. I work in a weld shop as a fabricator by day, but we really don't do any tube work or TIG welding. That part is new to me, learning as I go.

    But it gets better, I still have that back section to cut out and re-gusset. Should be a piece of cake though, compared to the bending and coping of that compound angle of the motor cradle.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  8. #68
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Oklahoma
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    Finally got my frame finished folks! That was a bunch of welding, cutting, and fabricating but its done.

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    Made some skid plate mounting blocks

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    And built up the worn steering stop

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  9. #69
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Oklahoma
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    So, as some of you may have seen in my other thread...my motor paint turned out a flop. Looked great till I pulled the masking tape and half of it flaked off. Multiple issues, probably including operator error contributed to this issue. My plan is to turn some plugs on the lathe and use a hot pressure washer to remove the paint, then prep and repaint again.

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  10. #70
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
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    I've been pondering the best way to modify my rear bearing carrier to convert it to disc brakes. My solution is to build a completely new one from scratch. I will R&D (rip off and duplicate) the mounting brackets in CAD and cut them on the CNC plasma table, turn my own custom housing and design and plasma cut a mounting bracket for whatever caliper I end up using. Should be less time and look wayyy cleaner than modifying the old housing. Stay tuned.....

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  11. #71
    Join Date
    Jul 2005
    Location
    az
    --
    1,949
    that's a chain drive right? easy idea i have is to just use the original drum as a hub to mount a disc on. might need a 1/8 inch or 1/4 inch washer to move the disc out. bolt the disc to the brake hub and build a mount for a caliper. jim
    81 185s
    82 185s with 85 200s motor
    suspended 185s
    85 atc70
    1984 200s
    85 350x 3rd owner
    and a 72 ct70

    projects coming along

    85 200s
    81 suspended 185s (can't believe I came across 2)
    1982? 185s

  12. #72
    Join Date
    Apr 2014
    Location
    Edmond, KS
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    2,531
    Maybe you could find a wrecked, chain drive quad with disc brakes for cheap. Then cut the carriers off and weld the quad carrier onto your trike and use the rest of the quad parts as well. I'm NOT talking about the cheap, Chinese quads.

  13. #73
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
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    Jun 2015
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    Oklahoma
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    Yes, its chain driven. A 200X rear rotor and hub fits the axle, same spline. Thats what ill be using, just have to make a small spacer to make up for the narrower width vs the drum. The caliper used will be a XR650 front caliper dual piston, cause I can. And that's what I have available.

    I could use another carrier, or mount it to the existing housing somehow, but wheres the fun in that. Thats not how I roll, I'm going to build one better than you could ever hack together from stock parts. And it won't take much more time either compared to modding an existing one. Also, doing it the way I'm thinking, I can incorporate a small lift and stretch directly into the carrier mounts, like a true bolt on lift kit, no welding necessary. Whether I do that or not remains to be seen, we'll see what I come up with first.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  14. #74
    Join Date
    May 2006
    Location
    The Open Road
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    4,729
    This thread is awesome

    Nice work on the frame, sir!

    Sent from my Z958 using Tapatalk

  15. #75
    Join Date
    Oct 2002
    Location
    Northeast
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    17,438
    You're lucky that the 200X splines are the same. When I made my ATC70 disc setup I just mounted a ATC70 drum in my lathe and turned it all off aside from the splines and made a shoulder on the hub. I welded on a flange and turned it straight in the lathe and found that an 82 250R disc was the perfect size.

    I had some kind of NOS japanese caliper laying around and used that. If there's a will there's a way...

    There's a dude on Facebook selling ATC 70 disc brake kits and he is charging almost 300$ and uses China brake parts
    All our government does is distract us while they steal from us, misspend our tax $ and ruin our country

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