home built full suspension ATC70

[2002Gimp]

I took a £20 garden find ATC70 from this


to this


Then after some of this



I decided I really really need suspension

So thats where this thread starts, gonna guide you through the process of fully suss'ing an 80's Honda using parts that don't fit, through the media of pictures...

First stop was the donor frame, now it would of been easier to grab a pit bike frame and work with that as they use Honda copy engines which bolt in, but I wanted this thing to be tiny and really chuckable, so I ended up with a KTM SX50 Junior frame. This things made for kids ages 3-7 to get an idea of its size.


Next step is to get the engine mounted, easy hey

start with a mockup



once happy it 'might' fit, add a few more bits just to be sure


Grab some steel (handily cut from the old frame) and mount that powerhouse

[2002Gimp]

After some lunch and a beer, sit down and think about getting the rear end sorted. Cant use the KTM swingarm, far to wide and not industrial enough looking for my liking.
Look around the Garage and find that bit of Suzuki SJ chassis you were keeping, but didn't know why. Look, fits perfectly inbetween the bearing carriers




Run out of MIG wire, so cant weld it to the frame, so just mockup, sit back and think aboiut blasting through the fields on it...



Oh, tight


Set the ride height, you know, just to see how she'll look


10 inches of clearance at the lowest point


Stick the old tank and seat on and realise they wont work >


Thats as far as I got, not bad in one day, I would of had the rear end done and swingin, but like I said, I ran out of consumables!

Stay tuned...

[the great gazoo]

Wow, that's a good bit of work for a day-You say that's a KTM frame? Which model? And I'm curious tosee what you're going to do for triple clamps, very nice work & ,

[2002Gimp]

Its a KTM SX50 Junior frame, designed for 3-7 year olds

I chose it as its small, its actually smaller than the original ATC70 frame


I'm gonna have to have something lasercut from steel for my Yokes

[Brockey]

Impressive. Now I thinks I'm gonna attempt to suspend my 70. I gotta go to a local scrap yard tomarrow so I'm going go donor frame hunting. Keep us posted.

[Billy Golightly]

Looks good...but you should consider lowering down the motor where the end of the sprocket shaft is on a straight and level plane with the swingarm pivot area. You'll save yourself a lot of headaches down the road.

[200x Basket]

yep, the output sprocket, pivot bolt and rear sprocket all need to be in a straight line.

looks intersting!!

[KASEY]

THE motor is so long it looks like the forks are going to hit it,,, it looks short judging from the seat and tank,,, looks like you will be setting behind the rear axle too,,,,

[2002Gimp]

I think its just the angle of the picture above. The sprocket is pretty much inline, maybe slightly high due to the frame being in the way. I think i'll get away with it though, there's a good inch and half clearance either side of the swingarm pivot.

You can see better in this pic, the red lines and in line with the swingarm and the blue line is the chain run. On full compression the chain might hit the swingarm pivot, but i plan on having some nylon here and it wont happen that often...