Flat track pauterbuilt pj1 build

[90crazy]

It's time to start working on this thing! Forks are getting rebuilt and polished. Powdercoating most parts except the frame and triples gloss black. The motor will start as a 1980 110 and the plan is a 180cc Pauter with hi/lo conversion and manual tranny.:twisted:
Still not sure of color scheme but the low pro fenders and tank will probably get black with gold metal flake with large PJ1 emblems.

[Vealmonkey]

Very interesting... I'll definitely be keeping an eye on this thread.

[ironchop]

I vote yes on this thread

[shortline10]

Very nice i'll be watching this one also .

[90crazy]

The internals of the forks are in pretty rough shape.

[Mr_RPM]

yay, my fav. 110 builds rock

[Vealmonkey]

Not the best, but not by far the worst I"ve seen either. LOL What forks are those with the axle hole on the bottom like that and not have the 2 stud bolt on clamps? I don't have any of that design. And now I have those yz80 fork tubes that I need to get all the rebuild stuff for.
Heck, it's hard enough trying to get all the rebuild parts for the 350x fork tubes and some of those parts are discontinued now.

[90crazy]

Not the best, but not by far the worst I"ve seen either. LOL What forks are those with the axle hole on the bottom like that and not have the 2 stud bolt on clamps? I don't have any of that design. And now I have those yz80 fork tubes that I need to get all the rebuild stuff for.
Heck, it's hard enough trying to get all the rebuild parts for the 350x fork tubes and some of those parts are discontinued now.
They are 31mm so I believe they are mid to late 70's yz 80 forks. I know they used CR 80 forks too. I don't know what size they are tho. These forks and triples were together with the frame when it was built for some race team back in the day:cool: (at least thats the story I got:p).

[Vealmonkey]

If they are yz80, they are way different than mine. Mine are early 80 yz forks. I need to source the internals for mine and sent some bits out to get polished and anodized back to stock appearing. Let me know how hard or easy of a time you have finding the internal pieces for your forks. I hope Mymint can come up with some pics of my bike all in one piece and racing or at the races. How many of those disc brake setups you have now? I have to get mine straightened out right. I was also thinking about changing the cable drum brake out in the front for a juice disc or maybe just running no front brake. You seem to posess the one thing I'm lacking right now, a clear uncluttered work space. LOL Get going on this beauty and give me some inspiration. I've had some vacation time and have been working on fixing up a couple things and doing some clean up, which is a major deal in my house. LOL

[90crazy]

6MM piece of aluminum to make the spacer plate for the big stroker:naughty:

[90crazy]

If they are yz80, they are way different than mine. Mine are early 80 yz forks. I need to source the internals for mine and sent some bits out to get polished and anodized back to stock appearing. Let me know how hard or easy of a time you have finding the internal pieces for your forks. I hope Mymint can come up with some pics of my bike all in one piece and racing or at the races. How many of those disc brake setups you have now? I have to get mine straightened out right. I was also thinking about changing the cable drum brake out in the front for a juice disc or maybe just running no front brake. You seem to posess the one thing I'm lacking right now, a clear uncluttered work space. LOL Get going on this beauty and give me some inspiration. I've had some vacation time and have been working on fixing up a couple things and doing some clean up, which is a major deal in my house. LOL
Only have one of those disc brakes now. Not gonna use it on this build tho. My buddy runs a shop and said they should'nt have any problems getting those forks rebuilt. I guess we'll see

[90crazy]

Chucked an axle up in the lathe to check straightness and polish. Lookin good!:naughty: Sounds like some parts are done at the powdercoater too.

[swifty]

that frame looks real close to mine the 110 in my display pic, you even have the same tank as mine below it! lol now i see why mine dose not have the front motor mount wow is that one long and low! ill be watching for updates also on this build looks like a good one.

[ratvespa]

6MM piece of aluminum to make the spacer plate for the big stroker:naughty:

let me know how you get that pauter big bore kit to work for you, I have the same one sitting on my bench, going to build a motor for it soon.

[ratvespa]

that frame looks real close to mine the 110 in my display pic, you even have the same tank as mine below it! lol now i see why mine dose not have the front motor mount wow is that one long and low! ill be watching for updates also on this build looks like a good one.

You should at leasy have holes for the front motor mount, I know they did that so you could fit diffrent style engines in there, there are single hole and double hole style. Im sure you could find a water jet guy to cut you some for cheap.

[90crazy]

So I got a few things powdercoated black. New tapered steering stem bearings and new axel bearings and seals. Trying to use all new zinc plated metric fasteners to match the zinc frame.
Also picked up this Pauter cylinder. It has the 6mm spacer plate already casted into the cylinder. I was told these were made by Pauter specifically for the 180cc motors. This one has a thicker sleeve and a oil passage and tapped hole for an oil cooler setup which I will be running.

[Vealmonkey]

I have one of those cylinders, it doesn't have a predrilled hole in it though. Not sure if that hole is original to the cylinder or not, but I don't think it is. I could be wrong. Thanks for posting, I'd been looking forward to the next installment of this build.

[90crazy]

Gonna use a little of both of these for this project. One with the hi/lo conversion and manual tranny has the cases bored out to fit a 61mm cylinder but has a smaller cylinder and a 58mm stroker. The other one's cases are not bored but has a larger stroker. Not sure what cams these are but they look similar to each other.
Also a pic of the head side cover oil outlet. I plugged the spot where a brass 90 was threaded in. My second line for the oil cooler will come directly from the pauter cylinder.:naughty:

[90crazy]

Well, I finally got the stuff back from getting polished and it is sweet! The old skool offset 2 piece rims look great on the new replica old skool flat tracker tires. Thanks Mike, for the idea:lol: They are wide and hold the rubber out nice and flat.:naughty:
The fork tubes are now in the process of getting put back together with new seals and oil.

[H95Shooter]

is that farm homeade i know dumb question

[swifty]

no its a aftermarket frame same as the one in my display pic... sorry to jack the thread lookin good

[shortline10]

Very nice !!!!!!!!! Them wheels look like they cleaned up like new .

[H95Shooter]

sigh i was hoping i could buy one any body making them or would i need to make one the hard part for me would be making the real axle part

[H95Shooter]

needed a free bumb

[90crazy]

Got my forks rebuilt and installed. Just got the front tire on the new front rim. Now I need to cut the front axel spacers and install the front tire. Got the aftermarket footpegs installed on the freshly powdercoated bracket.

[shortline10]

Looking good !!!!!!!!!!!!!!!

[swifty]

cant wait to yours done with fenders, is this frame actually called a pj1 model or just going to be pj1 themed?

[swifty]

heres a diffrent pic of mine with that frame for some inspiration:p, i need to do some cleaning on mine but its done and runs, and i need to add the aluminum front wheel also

[HONDA_ATC_FREAK]

That is one sweet ride swifty it's like a rat rod trike :D I love the shifter is that a hurst. I think the tank would look better in a nice cherry red though. The upside down bars are sweet to does it bust your knuckles in sharp turns or doughnuts.

[swifty]

Thanks, yeah i got a flat black tank also for when i take it to vintage torque fest, its a big rat rod show in april, im also getting the tank on it repainted, the shifter is a car 4 speed hurst with a b&m handle, the bars are actually on correct they are motorcycle cafe racer bars, just wanted a diffrent look and this style frame made it work, i can wait to see 90crazy's when its finished to see a diffrent style of this frame build. keep up the progress 90crazy a lot of us are excited to see yours done!

[90crazy]

I got the oil cooler mounted the way I wanted along with the motor mounts. This is not the tank I'm going to use, just making sure I have clearance for the cooler.

[shortline10]

Sounds like your putting a big motor in the puppy :naughty:. Looking good :drool:.

[swifty]

id might be interested in buying that tank if you want to sell it, mine has dents was gona get it repainted, anyway let me know if you do

[Daddio]

This looks like a really neat build. Pretty interesting to see how much old school stuff you guys have come up with. I have a Bandito frame and I've been kicking around some ideas on which direction to go with it. Too many Ideas. Keep the updates coming!

[90crazy]

Sounds like your putting a big motor in the puppy :naughty:. Looking good :drool:.
:twisted:maybe so.....

[ironchop]

nice progress...lot`s of trick parts

looking forward to more

[Shorty]

What color did you use to repaint that gas tank?

[90crazy]

What color did you use to repaint that gas tank?
The tank in the pic along with the one on the trike on my avatar are both original 1978 tanks in very good condition.

[90crazy]

Just set it down for a mock up. Even tho it will look nothing like this, I was anxious to see it on the ground.:lock:

[HONDA_ATC_FREAK]

coming along nicely

[thestud25]

Well, I finally got the stuff back from getting polished and it is sweet! The old skool offset 2 piece rims look great on the new replica old skool flat tracker tires. Thanks Mike, for the idea:lol: They are wide and hold the rubber out nice and flat.:naughty:
The fork tubes are now in the process of getting put back together with new seals and oil.

What are these tires? I have a trike that I am I seriously thinking about making street legal and these tires look like they would be good to throw on it.

[shortline10]

Looking good !!!!!

[motoman1012002]

it is lookin good

[tri-shee]

NICE ,Looking good man

[90crazy]

Just picked up this NOS S&S exhaust. I guess I'll have to wait till the motor is in before I decide if I'll use it on this build or stay with the supertrapp.:wondering It is definately a little longer but it sure looks good:naughty:
I think I'm leaning toward using it on my duner trike. It looks more suited for that. Now I could use the BAPP stinger on my pauter build:wonderingnot sure tho.

[shortline10]

So your the one who got it :lol: . Nice Pipe :drool:

[90crazy]

Another cool add on. And yes it's a stock hub that I drilled and polished.

[90crazy]

I'm having 3ww member Shortline build the motor for this project from the ground up. It looks like its coming along great!:twisted: The crank is a NOS H&S 61.5. The piston is a 61.75 custom cut honda piston. The head in the pic is my Pauter head with the very large intake valve. And you can see the needle roller bearing which it has on both ends. It uses a KH90 grind cam. You can see the difference of a stock head versus the Pauter head. It also has the SL90 hi/lo conversion and manual tranny.

[honda250sx]

Very nice!

Mike can you provide the bearing numbers on the bearings in that head?

[90crazy]

Very nice!

Mike can you provide the bearing numbers on the bearings in that head?

They are torington bearings. GB168 and GB108.
tolerances are...
GB168 SHAFT 1.0001-.9998 HOUSING 1.2450-1.2454
GB108 SHAFT .6251-.6248 HOUSING .8075-.8078
They are kind of hard to find.

[honda250sx]

Two sets of bearings on the shelf at my bearing guys. Headed to get them right now on lunch. LOL He opened for business when dirt was clean. I love these guys.

[shortline10]

Defiantly going to be a beast at 185cc :w00t:

[90crazy]

The exhaust valve is stock and the intake valve is from an XL185 and has been shortened.

[motoman1012002]

looking good

[mmartin]

Wow this is a very cool build! I'm definitely going to keep watching this one. Look forward to more pic's and updates:naughty::D

[honda250sx]

Super Trick!!

[shortline10]

Hope you have a big recoil handle :lol: because this ones gonna need it :w00t:

[Vealmonkey]

I do like that very much. That PM cylinder makes me all tingly. It really makes me want to get one of my engines together. Inspiring.

[motoman1012002]

id like to have one of the top ends off there

[jadleybray]

This a cool motor build!!!!

[willreed03]

How come the exhaust valve has a big notch in the top? And I have that same Craftsman yellow and red plastic ended hammer lol

And the build looks awesome!!

[90crazy]

Need to do some polishing and carb cleaning but I think this is the setup I'll be using on this motor if it likes it. I believe the intake is a Posa...:wondering Am I right Mike?

[shortline10]

Yep thats a POSA manifold , measure the intake side of that carb to see if its big enough for this beast , 24 or 26mm ? Note the longer the manifold it usually helps with the higher RPM'S and hesitation issues . Dont you have A nice long BAPP intake for this build its a little better manifold than that posa .




Need to do some polishing and carb cleaning but I think this is the setup I'll be using on this motor if it likes it. I believe the intake is a Posa...:wondering Am I right Mike?

[lardog]

Hope you have a big recoil handle :lol: because this ones gonna need it :w00t:

Its definately lookin good.

[90crazy]

Yep thats a POSA manifold , measure the intake side of that carb to see if its big enough for this beast , 24 or 26mm ? Note the longer the manifold it usually helps with the higher RPM'S and hesitation issues . Dont you have A nice long BAPP intake for this build its a little better manifold than that posa .
Is this the long BAPP intake you're talkin about?

[shortline10]

Yep thats the good one .


Is this the long BAPP intake you're talkin about?

[90crazy]

This chrome cover fits over the stock recoil. And, I came across this NOS Big Al's recoil handle. It's the same size as the 185 handles I usually change the 90/110 handles out with. I have another one on my red 90 but this one is new:naughty:

[shortline10]

Looks good !!!
Did you get the big box yet ;)????:w00t:




This chrome cover fits over the stock recoil. And, I came across this NOS Big Al's recoil handle. It's the same size as the 185 handles I usually change the 90/110 handles out with. I have another one on my red 90 but this one is new:naughty:

[90crazy]

Looks good !!!
Did you get the big box yet ;)????:w00t:

Hopin it'll be on the doorstep when I get home!

[shortline10]

:w00t:I just checked the tracking # and its sitting on your doorstep shens.




Hopin it'll be on the doorstep when I get home!

[atc007]

GOOOOODDDDD Stuff!!!!

[90crazy]

:w00t:I just checked the tracking # and its sitting on your doorstep shens.

I got home last night and the mail man took the package back to the post office and that's where it's sitting now. Guess I'll have to get there today!

[shortline10]

Yep , with all that insurance it will need a signature .



I got home last night and the mail man took the package back to the post office and that's where it's sitting now. Guess I'll have to get there today!

[90crazy]

Got the motor in, foot pegs on, shifter on, chrome recoil on last night. It's comin together but still needs alot odds and ends and fine tuning. Decided to run my BAPP stinger exhaust for sure. It fits this build perfect! I'll get some pics up soon.

[Super350]

where did you get the race/number plate on the front? Im talking about the one in your mock up pic. thanks

[90crazy]

where did you get the race/number plate on the front? Im talking about the one in your mock up pic. thanks

Got it from another member on the site. Might consider selling it.

[90crazy]

A few progress pics.

[shortline10]

Looks awesome . Remember to do a few heat cycles before you rip on it she's got a nice tight bore .
A few progress pics.

[dcreel]

Looking good man..

[90crazy]

Looks awesome . Remember to do a few heat cycles before you rip on it she's got a nice tight bore .

For sure! It might be a little while before I run it cuz I'm waiting on my tank to be painted!
Pretty sure I'm gonna use this decal on this tank. Maybe customize it a bit but not sure. Any other ideas or opinions...:wondering

[90crazy]

41 tooth rear sprocket for this one. I got the oil cooler lines ran too.:naughty:

[motoman1012002]

so what size of carb are you running

[90crazy]

so what size of carb are you running

Gonna start by trying a 24mm mikuni.

[motoman1012002]

any more work done on this

[motoman1012002]

So what the mods done to the stock head for pauter

[motoman1012002]

any more good hard work done on the bike

[90crazy]

any more good hard work done on the bike
Pics coming soon... Got the new twist throttle and grips on along with a new throttle cable. Got the carb and manifold hooked up to a new K&N filter. Changed my mind on the chrome recoil cover and went with the ribbed Trick Trike polished aluminum cover. The inside of the ribs have been painted black and the rest polished. Did the points cover to match.:naughty: Currently waiting on my seat and bar pad from cosmic quads. Working on installing the hardware to my low pro fenders. My tank is still out for paint.

[three_wheelin45]

thats one trick bike you have their sir!

[motoman1012002]

any new pics need some to get out and start mine

[90crazy]

Just a pic of a little more progress. Have not worked on this thing much lately, progress is slowing down...:crazy:

[motoman1012002]

low pros look good you did a great job with them

[90crazy]

Cosmic Quads have been working on this seat for me. :twisted: I have not received it but it's looking great. Now I just need the bar pad to match.:cool:

[R-tifacts]

just stumbled on this thread for the first time, looking good for sure! keep it up

[motoman1012002]

should got mosh to put gold in the pj1

[90crazy]

should got mosh to put gold in the pj1
I didn't want it to stick out too much. The top of the seat is a valvet type material. Should be pretty cool.

[90crazy]

Looks like my stuff is done!:cool:

[shortline10]

Wow they do very nice work !!!!!

[vartiak15]

wow that is some nice stuff there. how much was the seat cover? i need one made for mine. or i might go with the dratv cover

[vartiak15]

and what sprocket hub is that your using

[90crazy]

and what sprocket hub is that your using
The covers can vary in price depending on what is done. Contact Tammy and she'll let you know a ballpark price on what it is you are thinkin.
As far as the sprocket hub, that's the hub that was on the aftermarket axle. Should be the same style as stock.

[Stonewall]

Any updates?

[90crazy]

Any updates?
Have not done much with this lately. Been way to busy... New seat pan, NOS seat foam, and seat cover mounted to the fenders.

[250x]

Chucked an axle up in the lathe to check straightness and polish. Lookin good!:naughty: Sounds like some parts are done at the powdercoater too.


are you up for restoring my stock 200x axle? its straight, but needs a good facelift finishwise..

[90crazy]

Well I think with a little modification of a new fiberglass ATC 70 tank, and a little trimming of the front of the fenders, I think this will be a great fit for this build. I have a black one on order. I do need to drop my oil cooler about an inch to clear the tank too. Other than that, this build has not had much progress. Been way to busy!:crazy:

[90crazy]

Finally got my custom 70 tank finished to fit on this frame. It might hold a half gallon of fuel now!:crazy:
Still need to snap the seat down and wrap a few things up. I did get it fired last night. Now time for fine tuning and jetting. It sounds like a beast!:twisted:

[Vealmonkey]

You need to remove those rear fenders and get more detailed pics of how that tank is mounted please. Looks pretty good. Not to be mean, but you need a little something extra besides the black, make it stand out a little more.

[90crazy]

You need to remove those rear fenders and get more detailed pics of how that tank is mounted please. Looks pretty good. Not to be mean, but you need a little something extra besides the black, make it stand out a little more.

The tank is identical to the atc 90 tanks in the rear, how it has a large oval cut out and sits on the rubber peice to be strapped down.
The plan is to have some decals done but have not gotten that far yet.

[Vealmonkey]

Did you fiberglass the 90 tank rear mount on, or did you have it made like that? I can't wait to see it in decals.

[Bryan Raffa]

Looks like the seam let loose on the seat cover? right in front of the first snap...

[90crazy]

Did you fiberglass the 90 tank rear mount on, or did you have it made like that? I can't wait to see it in decals.
My fiberglass guy made the rear of the tank to replicate the 90 tank. I'll post pics at some point.

[90crazy]

Looks like the seam let loose on the seat cover? right in front of the first snap...
The cover is not yet snapped down. All seams are tight.

[90crazy]

Decided to try it on the ice and have had a few problems. The last being a broken recoil from the monster compression!:mad:

[90guy]

Man o man I love that machine!!!

[Keith Salyer]

Great build. Nothing stock left on that trike

[riverrat]

I want to see video of it on the ice :)