New guy with a SR500 build

Discussion in 'Old's Cool' started by SONICJK, Nov 20, 2013.

  1. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    I've been lurking here for quite some time just never posted.
    Figured the best way to introduce myself is to show you guys what I am currently working on.

    A little background, I've been building old bikes for the last few years. I think the 500 is my 5th build.
    My daily rider is a 75 400F that I did last winter:
    [​IMG]

    I picked up an SR500 from a guy at a bike show, long convoluted story, but eventually I got her home for 100 bucks. In rough shape:
    [​IMG]

    After a few hours of tinkering and she runs, quite well actually.
    [​IMG]

    Next up was tear down:
    [​IMG]
    [​IMG]

    I fixed the rear of the ugly ass frame:
    [​IMG]
    [​IMG]

    Then I started blasting:
    [​IMG]

    Here I got a bit side tracked powder coating a bunch of parts, some of them got used later some are just now pretty scrap.
    The color scheme will me metal flake bronze, flat black, and creme white:
    [​IMG]
    [​IMG]
    [​IMG]
    At some point in here I rebuilt the engine:
    [​IMG]
    And got some Shinko 712's
    [​IMG]

    Decided since this was going to be a road toy but with occasional jaunts into fields to do some powerslides and whatnot i got some 2009 WR250R front forks and some cheapy shocks that didnt get used
    [​IMG]
    Lowered them 3"
    [​IMG]
    [​IMG]
    [​IMG]

    Bent up a rear hoop:
    [​IMG][​IMG]

    CHanged up the top triple a little:
    [​IMG]
    [​IMG]

    Built a seat from 3/16 aluminum:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    And then things got interesting:
    [​IMG]
    [​IMG]

    OOPS:
    [​IMG]

    Bent up a new rear subframe from .120 wall 1" tube:
    [​IMG]
    Welded up the gaping holes I left in the frame:
    [​IMG]

    Narrowed the swingarm about 8mm tacked the subframe and built some shock mounts
    And this is how it sits as of today:
    [​IMG]
    #1
  2. JonW

    JonW Been here awhile

    Joined:
    Apr 15, 2009
    Oddometer:
    159
    Location:
    Sydney, Australia
    I like it! I also know only too well how you start off with an idea and then something comes along and you end up changing your mind. Its your bike so hell why not, nice to see that in action!

    I have KTM forks on my XT500, shortening them was easier than I expected, mostly through threads on here, thanks those who posted those threads!
    #2
  3. 16VGTIDave

    16VGTIDave blame Reaver...

    Joined:
    Nov 4, 2012
    Oddometer:
    599
    Location:
    Drumbo, Ontario, Canada
    Nice! I transplanted the same swingarm and suspension into my '82 Maxim 400 this spring. :clap Had to install a stiffer spring as I weigh just a bit more than 190 geared up and the stock spring wasn't up to the task. I'm thinking of rear frame mods this winter. I'll be watching your progress. :thumbup
    #3
  4. pvangel

    pvangel Team AARP

    Joined:
    Sep 29, 2005
    Oddometer:
    2,652
    Location:
    South Salem, NY
    Very cool, nice work!!!
    #4
  5. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Thanks guys I appreciate it!
    Its been fun so far.
    Working on getting a tig to finish up the welding and make some more aluminum parts.

    I haven't finished the welding to see if its going to work for me or not, but its from a 2007 ex250 which weights the same as the stock SR (mine should weigh considerably less) and I'm only about 150, so I am hopeful. Eventually I'll probably replace it with a nice shock but for now I *think* it should be fine.
    #5
  6. bk brkr baker

    bk brkr baker Long timer

    Joined:
    Jul 19, 2006
    Oddometer:
    6,076
    Location:
    The Bluegrass
    Sometimes , new guy with a ? whatever build is disappointing.
    Not this time !
    SR 500 's are great bikes and thanks for getting this one back in shape , and beyond with well considered mods.
    Keep it up and I'll be watching and learning .
    #6
  7. dlmarquez

    dlmarquez dlm

    Joined:
    May 13, 2004
    Oddometer:
    79
    Location:
    Tacoma Washington
    :D. Very nice! Subscribed!
    #7
  8. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Ha! Yeah I know all too well.
    I'm only "new" here. I frequent other places :freaky

    Hopefully going to get the shock mounts and all welded up tonight so I'll see how the spring weight is.
    #8
  9. SloMo228

    SloMo228 World Class Cheapass

    Joined:
    Sep 22, 2012
    Oddometer:
    1,876
    Location:
    SE Michigan
    Very cool. Looks like you know your way around a shop!
    #9
  10. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Pulled the trigger on my tig tonight so final welding should commence soon.
    But for now I made some gussets for the seat:
    [​IMG]
    [​IMG]
    [​IMG]
    #10
  11. Canuman

    Canuman Crusty & Unobliging

    Joined:
    Jun 21, 2008
    Oddometer:
    4,674
    Location:
    The Palace of the People, VT
    It's good to see a guy who appreciates the old stuff and does such nice work on it. I dropped off an '81 XT 250 that was surplus to my needs with inmate Jackpiner57, and his eyes lit right up. It wasn't cosmetically pretty, but the tank was straight and spotless inside, the head and swingarm bearings were tight, and it had a squeaky clean carb on it. Something about the lines of the old singles . . .

    Looks like this one is going to be very pretty when you button it up.
    #11
  12. Hohmie

    Hohmie Been here awhile

    Joined:
    Jan 23, 2013
    Oddometer:
    721
    Location:
    Bend Or
    Way cool! I like it.
    #12
  13. dhallilama

    dhallilama Been here awhile

    Joined:
    Apr 3, 2012
    Oddometer:
    675
    Location:
    Portland, OR, USA
    rad little SR!
    #13
  14. Pigford

    Pigford British

    Joined:
    Sep 27, 2009
    Oddometer:
    1,000
    Location:
    North Dorset, UK
    Thats looking good :clap

    Where that web plate sits under the seat rail - don't weld fully into the corner... always leave room for movement/expansion to avoid stress at those tight points.

    [​IMG]
    #14
  15. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Thanks pigford!
    I'm also going to move the gussets out the the inner or outer side of the tube for more strength haven't decided which yet.

    I appreciate the comments guys!
    #15
  16. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Waiting on the tig I decide to build a stove to keep my shop warm. Propane heaters are too expensive an I Have an inexhaustible supply of wood (own a furniture company)
    So:
    [​IMG]
    [​IMG]

    If anyone has ever considered one of these, go for it. It puts out a ton of heat.
    I will put a squirrel cage fan blowing into the top section, hopefully keeping superheated air blowing out the vent in the front into the work area.
    #16
  17. PhiSig1071

    PhiSig1071 What's ******width?

    Joined:
    Apr 9, 2008
    Oddometer:
    2,573
    Location:
    Tucson, AZ
    That's just cool. Er, hot? :lol3
    #17
  18. Canuman

    Canuman Crusty & Unobliging

    Joined:
    Jun 21, 2008
    Oddometer:
    4,674
    Location:
    The Palace of the People, VT
    I had one of those double-barrel stoves in my last shop. It was 40' x 60', with 14' ceilings, and you could get the place hot enough to start sweating at below zero.

    Just make sure you've got steel, not pot metal barrel bungs. The pot metal melts, and the thing takes off like a rocket!
    #18
  19. SONICJK

    SONICJK Adventurer

    Joined:
    Jul 22, 2013
    Oddometer:
    28
    Location:
    Bell Buckle, TN
    Thanks canuman.
    I think mine are steel, but I know what you mean! I took the large bung out trying to let a little more air in. When I closed the door smoke built up, billowed out the hole and then lit and it was like a flame thrower for a second I about shit myself!
    #19
  20. Canuman

    Canuman Crusty & Unobliging

    Joined:
    Jun 21, 2008
    Oddometer:
    4,674
    Location:
    The Palace of the People, VT
    Yep. You've had the experience. We built ours with the bungs toward the bottom. Everything went nicely until one cold day when we decided to put the wood to 'er, and the zinc bung just turned into soap. With that big old draft open, everything started roaring and shaking. I swear we could see the fire through the sides of the stove. Luckily, we found a stick of wood of the right diameter, and plugged it. Next day, we had steel in and didn't have a problem afterward.

    Likely the cheapest high-output stove that can be found, if you're not particular about EPA.

    #20