figgy Posted January 25, 2020 Report Share Posted January 25, 2020 Looking forward to your build pictures as it progresses. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted January 25, 2020 Author Report Share Posted January 25, 2020 I am looking forward to any progress. Mate just rang - returned from a week in Italy. "I will do it tomorrow and drop it off". Priceless. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted January 28, 2020 Author Report Share Posted January 28, 2020 After swearing on a stack of bibles that it would be here yesterday, Chris finally arrived tonight at 8.30 - only 6 1/2 weeks late. It looks messy, but just needs cleaning and blowing out, the thread in the top hole needs a tap running through it and drilling / tapping a new thread at the bottom (the bare alloy in the centre of the photo - currently solid alloy) - to fit a crankcase guard (protects the crankcase when a final drive chain snaps). Then it can get painted and rebuilt. Quote Link to comment Share on other sites More sharing options...
Paddy Galore! Posted January 29, 2020 Report Share Posted January 29, 2020 you'd think that as he's a mate he might have cleaned that up a bit for you I've just got my carbs back for the vf, another mate, we'd discussed up jetting, lifting needles, balancing etc, but £70 didn't include jets apparently, i'll remember that when he needs a favour... Quote Link to comment Share on other sites More sharing options...
Gordon R Posted January 29, 2020 Author Report Share Posted January 29, 2020 I was just grateful to get it back. He is the slowest worker on the planet. All cleaned now and the hole has been drilled and tapped. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 5, 2020 Author Report Share Posted February 5, 2020 (edited) After tidying up the garage and getting rid of some tools / boxes - set about cutting the frame. The "Y" piece has been cut out and can be re-used. It just needs sliding further up the frame main down piece at the front. Put the spare engine into the frame to have a quick look. One of the bolts on the engine is hitting the bottom rail. I need to die grind a hollow to accommodate the engine sitting lower. Bought a spare frame to cannibalise box sections for front of the frame. I was originally going to buy some aluminium box section, but after Googling, found that it was 6000 series, rather than the 7000 series that the frame is made of. I am sure welders might say there isn't that much difference, but I would sooner use the same stuff. Have more photos to load, but can only load 2.76mb? Edited February 5, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
TIGHTCHOKE Posted February 5, 2020 Report Share Posted February 5, 2020 I admire your ingenuity, well done. Quote Link to comment Share on other sites More sharing options...
figgy Posted February 5, 2020 Report Share Posted February 5, 2020 (edited) 7000 is a zinc series aluminium with heat treating properties. After welding it should be heat treated to get its strength back. You can buy 7000 series box section from merchants like Smith's metals. Though you have a frame to cut up for mods. Edited February 5, 2020 by figgy Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 5, 2020 Author Report Share Posted February 5, 2020 It has let me upload some more. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 7, 2020 Author Report Share Posted February 7, 2020 Got the "Y" piece in place. Needs tidying up and making a lot more presentable, but just getting it to fit at present. There is enough wiggle room to fit two square tubes at the bottom of the "Y "to meet up with the frame. The frame joint will need sleeving for strength. When the new sections are done, just need to drop the spare engine in place and get it to the welder, to weld the joints and put four engine mounts and a couple of exhaust mounting points on the frame. Quote Link to comment Share on other sites More sharing options...
Paddy Galore! Posted February 7, 2020 Report Share Posted February 7, 2020 starting to get somewhere now gordon Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 9, 2020 Author Report Share Posted February 9, 2020 (edited) Tidied up the Y piece a bit - still needs far more work - and cut the square section tubes to correct length. Just have to use a hydraulic jack to push the top and bottom rails apart so the at the extended Y piece can be fitted. The joint will need sleeving. Edited February 9, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
blackbird Posted February 9, 2020 Report Share Posted February 9, 2020 I have a 250 exc (2 stroke) & that is an animal to ride, a 500 2 stroke must be bloody mental. 🤕 Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 9, 2020 Author Report Share Posted February 9, 2020 Myself and both of my lads have owned Cr500 Hondas. My lads used to race them. Quick, but not as quick as our KTM SX380 - absolute animal. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 21, 2020 Author Report Share Posted February 21, 2020 Dropped the frame off at the welders tonight. Should be back Sunday. Recondition the engine and place it in the frame, so that I can fabricate engine mountings. Some exhaust and radiator mountings to be welded on and the worst will be done. Quote Link to comment Share on other sites More sharing options...
ditchman Posted February 22, 2020 Report Share Posted February 22, 2020 way beyond my pay grade this....................love it cause it is always pristine at the finish ............. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 22, 2020 Author Report Share Posted February 22, 2020 I'm hopeful that it will look decent, but at the moment it is just a pile of new and old looking parts. Not decided about the frame. Invested in many tubes of Solvol Autosol, only to be informed by Junior that he had gone off the idea of a polished frame - now just polishing the swinging arm. Either powder coating or spraying the frame white, as the whole bike is an updated version of my eldest lad's 1995 Honda CR500 - which looked the same as this example. Quote Link to comment Share on other sites More sharing options...
figgy Posted February 22, 2020 Report Share Posted February 22, 2020 That looks the mutts nuts Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 25, 2020 Author Report Share Posted February 25, 2020 (edited) "Y" piece has now been welded in. Still needs a bit of finishing off, but just placed spare engine in the frame to check that the exhaust will go through the "Y" piece. Put spacers on swinging arm / back engine bolt to centralise the engine. It has slightly more exhaust port clearance than originally anticipated, so well pleased. Got engine, radiator and exhaust mounts sorted. Got to sort out the coil mounting - easy enough and then I am waiting for some aluminium collars / sleeves to arrive and frame will be back to the welders to finish off. The original frame box sections are roughly 1" square 10swg. When inserting a Y piece, the bottom joints are the weak point. The vibration from a 500cc two stroke sometimes causes the welds to fracture. It is a bit of belt and braces, plus more, but the Y piece has a smaller box section welded inside the 1" tubes, then the 1" tubes have been welded together, then a larger square section has been cut in half, wrapped around the tubes and welded around the top, bottom and down the seams. I don't see it ever breaking. Edited February 25, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
Gordon R Posted February 29, 2020 Author Report Share Posted February 29, 2020 (edited) Engine mounting fabricated and ready to weld this week, along with radiator, coil and exhaust mounts. Checked exhaust fit - need to weld on a bottom mount - decent clearance on the frame and engine. Edited February 29, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
TIGHTCHOKE Posted February 29, 2020 Report Share Posted February 29, 2020 Looking mighty good so far! Quote Link to comment Share on other sites More sharing options...
impala59 Posted February 29, 2020 Report Share Posted February 29, 2020 I have a DR 800 languishing in the garage awaiting my attention. I have been following this thread in the hope of inspiration but I’m just getting more scared of starting! I am in awe of your skill and perseverance, keep up the good work! Quote Link to comment Share on other sites More sharing options...
Gordon R Posted March 1, 2020 Author Report Share Posted March 1, 2020 CR500 devotees might notice an extra shaft below the kickstart - at the bottom. The spare engine was converted to right hand gear lever to fit in a motocross sidecar outfit. This one will need a bit of welding on the casing to cover the hole, when the shaft is removed. Our other engine is the standard, left hand gear change. Looking to get frame back to welder on Wednesday, so it should be ready by weekend. Been playing about with exhaust - CR500 has a 38mm OD, whereas the silencer is 46 ID. A bit of pipe shortening, plus a reduction spacer is the next on a long list. Quote Link to comment Share on other sites More sharing options...
Gordon R Posted March 6, 2020 Author Report Share Posted March 6, 2020 (edited) Got frame back - just dropped spare engine in to check fit. I have ground off the old weld in front of the bottom mounts and rounded off the new engine mounts, so it doesn't look as angular, as in photo. Still got a chunk of tidying welds up on the frame, before primer and paint. New exhaust mount bottom right - threaded for M8. Edited March 6, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
Gordon R Posted March 7, 2020 Author Report Share Posted March 7, 2020 (edited) Frame a bit tidier, with first coat of self etching primer. Another few coats of primer and then silk finish top coat, in white. Edited March 7, 2020 by Gordon R Quote Link to comment Share on other sites More sharing options...
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