DR 650 project: It's now a Beast!

Discussion in 'Some Assembly Required' started by DRjoe, Feb 4, 2009.

  1. DRjoe

    DRjoe Long timer

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    started working on the frame to.

    I pulled the bike apart and then stripped the paint of the frame.
    I bought some 3M paint stripper which worked really well.

    I decided i wanted to get rid of the support that goes from the bottom of the head stem to the back bone and replace it with a bit of lattice work.
    The main idea behind this was to stiffen the back bone a bit but also to create more room above the rocker cover so that it can be removed.

    I haven't finished yet because i ran out of mig wire. Please excuse the big ugly welds, I haven't mig welded steel for about 4 years and by eck don't it show.

    all these pictures make the frame look squint for some reason but its not. It was pretty much impossible to measure where to put the pieces so i did it all by eye.
    [​IMG]

    it still needs to have a few extra struts put i but you get the genral idea.
    [​IMG]

    [​IMG]

    I had to bend the bars like that to clear the carbs.
    [​IMG]
  2. LukasM

    LukasM Long timer

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    Holy shit.... go Joe! :pynd


    Unfortunately I am afraid we'll have to change the thread title soon. Besides the forks (the ones of from your EXC will swap right in :wink:), swing arm and wheels (EXC ones will fit with the right spacers :wink:), there really aren't any DR parts left.
  3. DRjoe

    DRjoe Long timer

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    Well the forks and shock aren't dr650 there drz400 so that counts them out the rear wheel is off a dr350? but the front wheel, swing arm, rear brake system and back bone is still dr650.

    I'm not going to start robbing bits of my exc to feed the my habit so stop encouraging me.

    so far the beast consists of the folowing bikes

    dr650= frame, swing arm, front wheel, rear brake
    drz400= suspension, front brake master cylinder, air box, sub frame, rear plastics.
    dr350= rear wheel
    gs500= engine, wiring, controls, front mudguard
    ktm 690 sm = fuel tank
    ktm 950se erzberg= mufflers
    honda cbr1100= front brake caliper
    honda cbr1000r= steering damper

    I think thats it. The good thing is the important parts are still suzuki.
  4. Travmoto

    Travmoto almost there...

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    Nice frame FrankensteinJoe! Pity that latice work will be hidden by the tank.
  5. JoeyBones

    JoeyBones Encouraging Entropy

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    I'm starting to think you could have just made your own frame from scratch and gotten exactly what you wanted!

    Nice work there... Do us a favor and don't sleep this week.

    Work on the bike take pictures post them up work on the bike take pictures post them up work on the bike take pictures post them up work on the bike take pictures post them up work on the bike take pictures post them up work on the bike take pictures post them up....
  6. DRjoe

    DRjoe Long timer

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    Ok i get the point you want more pictures
  7. NordieBoy

    NordieBoy Armature speller

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    Beer first.

    :deal :freaky
  8. DRjoe

    DRjoe Long timer

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    well if your gonna bring some round I wouldn't say no.

    What kiwi lands version of tooheys old.
    oh yea if your coming round you have to bring some 2mm welding rods to.
  9. Mezo

    Mezo Banned

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  10. DRjoe

    DRjoe Long timer

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    mmmmmmmmmmmmmmmmmm beer

    I could really do with a pint of McEwan's or even some cat piss Tennents would be nice

    [​IMG]

    [​IMG]
  11. DRjoe

    DRjoe Long timer

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    aaaaaaaaaaaaaaaaaah fucking fuck fuckers.

    I have just been looking into getting the bike registered and it turns out that its not as easy as i was first told.

    Before i started this project I did some research on the legality's of the engine swap and according to the qld goverment transport website If i want to change the engine and the engine is not offered by the manufacturer in the said bike I need to get a modification plate from an engineer.
    This was not a problem because the harley bike shop can do mod plates for engine changes or so he told me.

    I went to the transport office today to get the correct forms for doing the engine swap and while i was there i asked the lady at the counter what the modification code needs to be on the form she had no idea so she took my number and got back to me later in the day with some bad news.

    She said that no one realy knows how to go about getting the bike complianced because no one has ever asked for this to be done before but she gave me a couple numbers for engineers to talk to and she is posting a a few forms for me to fill out.

    The first engineer i spoke to didnt realy no what the go was and refused to get involved he did give me as much advice as possible but basically he said it would be a massive headache.
    The second engineer seemed to be a bit more clued up. He told me to fill out all the forms and send them away with as much information as i can on the different engines and he reckoned if there was enough information They might just approve it without an engineers certificate but they might request some more info and a certificate.

    Basically its doable but its going to take along time (MONTHS)
    Its not going to cost much more than i originally thought maybe $400 at most.


    Unfourtunatley me and the bike are signed up for our first race in 4 weeks so i think that i'll have to take another bike.

    bugger
  12. Travmoto

    Travmoto almost there...

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    Is the DR still on its current rego? Hmmmm
  13. DRjoe

    DRjoe Long timer

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    yep but i'll never get the bike past scrutinering at the race with different engine numbers also i really cant be asrsed getting pulled over by the cops and having to explain the different engine number.

    I've been given a few numbers to call so we'll see what i can find out.
  14. tileman

    tileman Been here awhile

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    I looked into frame modification ideas some time back and only found one engineer in Victoria that was willing to even talk about it.

    I do know of someone in Melb that has built a frame jig that can certify a major frame modification and has an engineer that he uses. He also told me that some of the custom harley companys here use bikes that are already registered so to not deal with the re cert???????? :deal

    I don't know for you but in Vic once a vehicle is registered then until that lapse's the vehicle doesn't need another roadworthy........ like you say, theres not really any way round this one..........

    But, as you have proved before, there is light at the end of the tunnel somehow.......
  15. DRjoe

    DRjoe Long timer

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    There are definitely ways round this little set back its just i don't have the time to get it done before the race which i have to be at by the 2nd of march.

    I have turned my attention the my ktm 520 I will attempt to make it capable of doing the long highway stints needed to get to and from the race.
    I'm going to fit the rear wheel of my dr to it and fit an oil cooler also seeing as i've got the time i can now make a better nav tower set up than i already have.

    Anyway thanks for all your suport guys and I promise I will finish the bike. I'll start working on it again in a month or so.
  16. Hardhead

    Hardhead Long timer

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    You're late....:D
  17. V8R

    V8R Been here awhile

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    if the dr is still current for rego, just submit an engine no. change.. now, ive got nfi how deep they check these things but if its just a 'change this to that', it should be sweet.. if they go as far as checking the series of the engine number and relating that to the make and model of bike, you may be in strife......
  18. tmotten

    tmotten Lefthand ride Dutchy

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    Mate, I went through some of this with QLD transport when I brought my Tenere in from the UK. First I had to prove to them it was a LHD.:huh

    Than to get the vin number I had to run it past a specialist engineer to check for ADR compliancy. He told me that there is no such procedure for bikes and that QLD transport even shows this on their system. I ended up getting the head of the department or something confirming this, but that wasn't enough for the cows behind the desk. As far as they were concerned if it wasn't on their system, it wasn't the case I had to fullfill the application as they knew it. It took several phone calls between me and their superiors before I could get them to talk to each other.

    I would just wing it with a different enginer number. But in the end, scrutineering would always be difficult depending if how fine the'd go over it.
  19. WILL_S

    WILL_S OUTLAW POSTIE 001

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    Joe maybe give this fella a call.
    R T Racing Mtrcycl Fabrctns

    <!-- google_ad_section_end(name=business_details_title) --> <!-- google_ad_section_start(name=business_details_tagline, weight=medium) --> <!-- google_ad_section_end(name=business_details_tagline) -->
    • ZILLMERE, QLD, 4034
    • Phone:phone (07) 3865 8591
    Many moons ago when i was stuffing around with choppers he new his stuff.He isn't a hd chopper shop, just a old school motorcycle fabricator/machinist.He might just know how to go about getting it rego'd.
  20. DRjoe

    DRjoe Long timer

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    oops.

    2nd of April