350X 400EX Transplant Build!

[Matt85'350x]

What are you using to view the DWG file ?. I can convert a DWG to a PDF if you send me the file. Anyone should be able to read a PDF file.

I'm using autocad. I can convert to pdf but then I would have to dimension them and they're not easy to dimension because of the shapes. I'd like to just keep the files as is.

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[BOB MARLIN]

Aren't they dimensioned on the autocad file ?. If so they should transfer to the pdf automatically.

[Matt85'350x]

Aren't they dimensioned on the autocad file ?. If so they should transfer to the pdf automatically.

No, not currently.

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[Matt85'350x]

Ok so nevermind my tank comment-turns out that's foolishness. Proceeding with my original plan. I had a moment where I was so displeased with the airbox that I was willing to do something totally different with my oil tank; the right thing to do here is to just fix the airbox. I also once again evaluated the possibility of using the down tube as the oil tank like an xr does. Well I got to see an xr up close this weekend and the difference is that the down tube is much longer than the x. Even with welding another tube to the front of the tank doesn't lend itself to having enough capacity. Remember the goal is to meet or exceed the 2 quart capacity of the quad; the math just doesn't work with the down tube. If you could go significantly wider it would work but then you run into the exhaust. Personally I still like my approach to it if you're willing to modify the air box. Otherwise hanging the oil tank off the side of the frame by the grab bar would work as well but that's also a nice spot to put the battery so a choice must be made. For now I'm working on the battery box, then working out the exhaust. As I've mentioned this is my first build, I'm not quick and sometimes have to redo things because of rookie mistakes. I'll keep going at it and the new goal is to be done before April.

[Merge_88]

Thanks for the update, I've read your thread a few times now. I appreciate the details you've gave through the build! Keep at it!

[Matt85'350x]

Ok few updates. I took the engine back out so I could replace the exhaust studs. 2 of them were rusted to the nuts and came out with them. I decided to just go ahead and replace all 4.


I got the engine back in now. It's somehow easier than the original 350x engine. I can have it bolted back in in about 15 minutes.

Onto the battery box. I bought a Polaris outlaw battery box for $17 shipped.

I had to lop off the top of the box so it didn't hit the plastics. Then I drilled 2 holes in the box and mounted it up to the grab bar

Few washers to space out the gap

Voila. Battery box came with the strap too


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[Matt85'350x]

Now the exhaust. I had to cut off the original muffler mount.



Now I have a problem with the exhaust. I have to do some bending so that the header isn't right on the frame and so the muffler doesn't hit the grab bar.


How would I go about slightly bending the exhaust?

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[TriMotoMan]

heat up the intermediate pipe with torch and bend it

[Matt85'350x]

Here is what I've been working on recently.








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[Matt85'350x]

These are just thin test gussets to check the fitup. This trike is not symmetrical. Seems the tolerances for the welds and such weren't very tight. Unfortunately both sides aren't the same. It's close enough that it should work but not quite the tolerance I usually would work with.

Cutting them out of the real steel soon.

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[Merge_88]

I wondered if you had made any progress. Looks like you have, keep at it!

Hey by the way, I got my motor mounts cut, thanks again for the drawings! I went ahead and cut an extra set too. I'm currently struggling with removing my swing arm/motor mount bolt from the 400EX, it's siezed!!

[Matt85'350x]

I wondered if you had made any progress. Looks like you have, keep at it!

Hey by the way, I got my motor mounts cut, thanks again for the drawings! I went ahead and cut an extra set too. I'm currently struggling with removing my swing arm/motor mount bolt from the 400EX, it's siezed!!

Wow those look just like mine!

Yeah I had to cut mine out. Common problem for these 400ex. I ended up destroying my swing arm but thinking back if I used maybe a saw zall maybe it wouldn't have been so bad. I didn't care though I wasn't about to risk that engine!

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[Matt85'350x]

Made some adjustments and got the final version cut out. Here's what I ended up with












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[BOB MARLIN]

Nice job on the gussets !. Way better than what I got from TPC.

[Matt85'350x]

Nice job on the gussets !. Way better than what I got from TPC.

Thanks for saying that. I posted this same thing on Facebook and immediately got told mine weren't as good as TPC. I'm not out to compete with them and never said anything about them. And I'm not necessarily done with them either. Did I miss any critical areas?

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