Clearance issues???

[Jmoozy27]

What I don't think you are understanding is that the reason you need gussetting by the shock mount now is because you cut the brace out. Put it back in, no issues.

Something tells me here we go again with somebody telling me the two areas are not dependent on each other for strength.

No, I understand it. The brace was causing issues, that's why I just cut it out. I wanted to either put something smaller that wouldn't interfere with everything, or find some other way to strengthen it. I like the idea of gusseting the mount instead. It will look cleaner and should kill 2 birds with one stone. I just wish I would have seen it before I painted it. Oh well, you live and learn.

[barnett468]

This is my plan, gusset both sides of the shock mount. I saw it this morning just before I made my cut. It should take care of that. I'm glad someone finally made that recommendation.

That bar you removed has nothing to do with the structural integrity of the shock mount per se . . In other words, your shock mount won't break much, if any faster, without the bar . . One of the bars main functions is to keep the sides of the frame from bowing inward under the force applied to the upper shock mount by the suspension . . It also obviously prevents the tubes from bowing outward when it is subjected to load which in turn prevents the frame from collapsing.

If you have room to move the bar up, which from this angle it looks like you might, it will have more affect than leaving it out and running a gusset from the upper shock mount to the side tubes instead...but I could be wrong cuz, I only know how to do engineering on a....KAWASAKI...The Fastest Bikes In The Universe.

[DohcBikes]

One of the bars main functions is to keep the sides of the frame from bowing inward under the force applied to the upper shock mount by the suspension . . It also obviously prevents the tubes from bowing outward when it is subjected to load which in turn prevents the frame from collapsing.

Even though it annoys me a little when somebody quotes someone and just says "^This.", that's about all there is to say there. You NEED THAT BRACE.

If you have room to move the bar up, which from this angle it looks like you might,

Looks to me like there is plenty of room especially when used in conjunction with ol deuces suggestion

it will have more affect than leaving it out and running a gusset from the upper shock mount to the side tubes instead...

I'm seeing no reason not to do both. I know damn well he's gonna want to jump this thing, especially with that razzle dazzle suspension i've been hearing about.

but I could be wrong cuz

You guys are cousins? Never woulda guessed it.

[barnett468]

I'm seeing no reason not to do both. I know damn well he's gonna want to jump this thing, especially with that razzle dazzle suspension i've been hearing about.

Oh most certainly, i was just referring to the function of the brace he removed, however, the last time I suggested how someone should gusset their frame AFTER they insisted they were going to do it and AFTER a few others suggested they should do it, someone else here said they should NOT do what I suggested, plus they said that my suggestion which might have added around 8 lbs, was really going to add around 20, would but I'm sure that's no big surprise.

[barnett468]

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Jmoozy, I suggest you use prefabulated amulite for the gussets so you don't turn the thing into a tank with the excessive weight they will add if you use steel.

[barnett468]

I'm seeing no reason not to do both. I know damn well he's gonna want to jump this thing, especially with that razzle dazzle suspension i've been hearing about.

You mean he got it from Race Tech? .

[oscarmayer]

I think every joint on the frame needs gussetting in my books and some extra supports added in. New idea. Add too and bottom braces to that area above and below the stuff. Problem solved and stronger than stock. Performance is not always about weight. When you got a motor 4Xs the power and performance of the stock one and weighs less than half. We can afford some extra frame weight for strength.
Gussetting every joint and re-enforce the down tube and steering stems. The swinger area also needs upgraded. Talk to Milner about him making you one of our swinger mount upgrade kits. That will stop the bolt hole from wollering and strengthen the swinger connection.


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[DohcBikes]

Gussets top and bottom side to side triangularly parallel and perpendiculerly won't do the job that brace was doing.

Maybe we should get an engineer in here.

[El Camexican]

Maybe we should get an engineer in here.

Unfortunately our site engineer is too busy arguing that tofu is better for us than venison and watching Bambi reruns.

Meanwhile here's a perfect chassis design that can withstand rapid acceleration, sharp turns and big jumps. Unfortunately it isn't bullet proof.

[Jmoozy27]

Okay, this is what I am going with. Please excuse the less than stellar machine work. My engineer has been a no show all week and I fired my welder for lack of attention to detail.

[YTZ drew]

It is my (limited) understanding that the function of that brace was to stop the vertical frame members behind the engine from bowing inwards towards each other (like getting pinched) when you land a jump, when the top and bottom members of the frame are being pulled vertically apart from each other due to the upward force presented by the shock mount, and the downward load presented by the weight of the rider on the footpegs. I would try to put the brace back in. I could be wrong, though. My suggestion for the air filter would have been (if I had seen this thread 3 pages ago when it started) would have been to use an 86-88 KDX200 airbox and boot, which turns sharply 90 degrees to clear the frame and the spring in its original application.

Interesting thread. I look forward to seeing the result. Based on your work up to this point Moozy, I have no doubt that the solution will have much thought put into it, and will be more than adequate for the job.

[oldskool83]

You could have a new intake make out of aluminum in the angle you need and then just run large carb radiator hose to the air box. I've done this and prob will be doing this on mine.

[Dirtcrasher]

You put on the gussets and then chopped out the bar.

If the plan is to strengthen the frame, then get it back in there.

I'd just move it up higher, grind it to fit well and try to get a nice weld all the way around it. You gotta be safe.

Even if your not much of a jumper, a CR125 is. And a stuck throttle may show you the week spots.

That flux wire looks like it's just putting blobs of melted wire on there, not real good penetration.

I wish you had a gas mig welder; They are very easy and when welded well, the welds are strong......

[Jmoozy27]

Okay, this is what I am going with. Please excuse the less than stellar machine work. My engineer has been a no show all week and I fired my welder for lack of attention to detail.

Sorry fellas I didn't realize that I forgot to post a pic with the above post so here it is:

[cr480r]

Forget the brace.