[dem3500]

So I've owned this bike for about 3 month with the intent of racing XC next spring. I've been toying with weather or to start a build thread. I figured why not! I'll try to get this thread cough up to where I am now. At the same time I'm starting a blaster for my daughter to race XC also. I don't know who's more excited about her racing, me or her... Haha
Here's what I started with.
ESR 310 PV TRX 5 pilpe
ROLL stem, pegs, brake lever
Stock suspension

The day I picked it up.

 

[dem3500]

I forgot about the brand new CBR radiator

 

[dem3500]

After I got it I noticed it had a pump gas dome. I bought a race gas dome for it and installed it. It didnt seem to have near the power i thought a race gas 110 should have. I did a comp test and I was right haha! Only 100psi. Yes that would do it! I got the engine bored, 2 sizes over and spent a small fortune on the ESR piston and was back in action. The guy that did the bore said it looked like it had been run for a long time worn out and that was probably why the cyl was beat up so much and needed to go 2 sizes over. Who knows lol. Its back running right, that's l I really care about

I picked up a set of stage 3's
And a set of 4-1 reinforced front wheels.
That in itself was a pretty bad ordeal and I kind of lost my ass in that deal. I waited over a month before I messed with the front wheels and found out they were NOT 4-1's like I was told! Oh well. You win some and you loose some. In the end I decided to keep and run the shocks. They need redone so I will send them out some time in the next few weeks.

 

[dem3500]

The weekend after I got the engine together I went riding with my two girls (14 and 10). I went off a small jump and my throttle stuck.....wide open! Yea that didn't end well! And the worst part about it was that nobody saw it! Haha. I think the quad might have done a back flip! Ha I hit the ground pretty hard.

I drove it back to then parking lot with a nice headache and only 3 turning wheels haha

 

[dem3500]

So I had plenty of bent and broke stuff but that's the name of the game so I decided to upgrade the spindles and brakes. I got a set of 450r spindles, brakes, and LSR billet hubs. I also broke the rear grab bar off and bent the front bumper. I rewelded the front bumper where it cracked from pulling it back straight. I also rewelded the grab bar but decided to go a different route. My garbage mad buddy found this grab bar in the trash. It didn't fit so I cut it all apart and rewelded it to fit. Yes....I weld a lot of stuff! I enjoy welding haha. I find every excuse I can to weld something. I also finally decided on a color. I did not want a red frame and I didn't really want to strip the red anodizing on all the nice ESR parts. I finally decided on goldtastic from prismatic powders. I do all my own powder coating. Same with the welding, I PC just about everything I can get my hands on! Haha.

This is a better pic of the gold. Synthetic light sucks for a lot of cors especially metallics.

 

[dem3500]

The frame is going to be gold with a clear coat, same as the bumper and grab bar. The nerfs, wheels, and upper arms are going to be black with a gold pearl clear coat. I donr have anything sprayed with the black yet.
I think I'm pretty much cought up to this week at least.

 

[dem3500]

Got a lot of nice parts on there buddy!

Yea, I jumped on this one. My buddy sent me a CL link and I drove 2 1/2 hrs to get it. $1700 with all those parts was a steal! It didn't run and was missing the power valve. Who knows why! But whatever. The spark arrestor was also completely plugged with carbon. And again who knows why haha

 

[dem3500]

looks like your going to have a nice R again after rebuild.being able to weld and powdercoat your own parts will keep the cost down a lot.i also do all of my own work.looking forward to see it completed.

Yea being able to all that stuff is the only reason I'm able to do what I do, otherwise I could probably only afford a bicycle! Haha

 

[dem3500]

Nice! Thats cool your daughters ride too. I can't wait to get mine running! I really haven't had a chance to look it over much since i got it, but will soon! I need to re educate myself on power valves and reeds and such....been a while since I have had a 2 stroke.

And yes my daughters riding is AWSOME to say the least!

 

[dem3500]

I bought a set of Rath 450r nerfs with heel guards from burns. These thigs are made real well. I was surprised about the quality. Very nice for sure. They took a little more work than I expected to get fitted but was all good in the end.
I cut off the existing peg mount

 

[dem3500]

1" od tube is what would fit in the nerfs. I ended up grabbing some 3/4" black pipe from the hardware store. It was a little bit bigger than 1" but some time with the flapper wheel I got it down so it would fit the nerfs. Getting it to fit through the frame was a little bit harder. There's a reinforcing sleeve inside on both side. All I did was spend some time with the die grinder so I could slide the pipe through. Not difficult but took a bit of time to finish.

 

[dem3500]

A pic of the sleeve on the left side. The right side sleeve was a little bit deeper.

 

[dem3500]

Got the front mount in as well


All done aside from final welding.

 

[dem3500]

Great looking bike...congrats for the new machine... It has some nice parts on the machine, I guess it will be on the tracks very soon.

Thanks! Yes I'll be on the track first thing in the spring!

 

[dem3500]

Thanks. I'll post up some more pics later today

 

[dem3500]

They lined up close, but not quite lol



Trimmed off the resivour bracket

I cut off the original mounting tab and drilled a hole big enough to fit over one of the mounts for the rear master cylinder


Got it tacked together

 

[dem3500]

I made lots of progress today. I finished tearing down the the bare frame despite the frozen swing arm bolt. A bit of heat and some patients did the job. I was about to cut it until I saw the price of a new one lol. I took a half hour and got it out in one piece.

While I was waiting for the swingarm to cool back down I did some repairing and beefing up of the upper motor mount. It was almost cracked all the way around on one end. I didn't like the small welds holding the tabs on so I added some of my own.



I wanted the tab to be welded all the way around also

 

[dem3500]

I wanted to get all the welding I could done. I can't get my frame to the sand blaster till next week.
I wanted to beef up where the heel guards attache to the rear sub. I didnt want to pinch the hollow tube with a bolt so I took some 1/2" solid round bar and drilled a small center hole through and welded it through the frame. That should work for some beefy mounts!

 

[dem3500]

got the nerf pegs finished welded

 

[dem3500]

got started on the gusset kit. and i slowly started running into crack after crack after crack haha yea yea yea normal R stuff lol