2021 Honda XR500R by N.A.P.A.L.M.

Discussion in 'Some Assembly Required' started by larryboy, Oct 1, 2019.

  1. larryboy

    larryboy Just obey!

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    I've already posted a little about it. I'll show detail, don't worry.
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  2. larryboy

    larryboy Just obey!

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    I'm installing tube clamps to allow a section of frame to be removed to access the valve cover. Suzuki has done this for 30 years to get the engine in the frame.
    Bigbore4, oldbmw and Nixels like this.
  3. Nixels

    Nixels Face fears - live life

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    But, but, but, won't that weaken the whole system? What about torsional forces!!!! :yikes














    :hide
    SlowernOlder and larryboy like this.
  4. larryboy

    larryboy Just obey!

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    I didn't get as far as I wanted today, but progress is progress!!

    Cleared my clunkers out of the way and got the tube bender and welders out. I'm in full build mode, I want @oldbmw riding this before summer.

    IMG_20210227_161650976.jpg IMG_20210227_161636282.jpg
  5. loganlexow

    loganlexow Been here awhile Supporter

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    Still so excited about this.
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  6. DiggerD

    DiggerD DougFir from SuperDuke Days

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    Seen that before.
    Dale cut up a CB750 Honda frame so he could do valve adjusts quicker.
    Used hose clamps to hold the frame tubes in place...sort of.
    Blew my mind when I saw what he did.
    larryboy likes this.
  7. larryboy

    larryboy Just obey!

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    IMG_20210228_194337931.jpg IMG_20210228_194344595.jpg IMG_20210228_194501916.jpg

    Nailed it first try. The trick is the mirror image. Had to stop and get some food so I can figure it out.
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  8. larryboy

    larryboy Just obey!

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    How a tube clamp works.

    IMG_20210228_194610656.jpg IMG_20210228_194843018.jpg
  9. larryboy

    larryboy Just obey!

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    Got the right spar made up. I'll tack the left spar first, then finish the right spar fitment to match. It's really difficult to find symmetrical points to measure off of.

    IMG_20210307_125525929.jpg

    I'm trying really hard to keep the coolant pipe in the stock location. If I have to I can flip it over and make it work.

    I might do a center backbone frame tube also, mainly to give me something to mount the tank to. It'll complicate the air box, but I think it'll be worth it.

    I've scheduled a week off work in a couple weeks to dedicate to this project. My goal is to have a roller with a seat I can sit on by the end of the month.

    I'm taking extra steps that I don't take when I build a dirtbag bike. Like sanding tubes where I'm going to weld, extra care on tube fitment and stuff. You know, doing it right.
  10. Nixels

    Nixels Face fears - live life

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    That's great looking! Congratulations on the progress!
    panterg55, oldbmw and larryboy like this.
  11. Ladybug

    Ladybug Bug Sister Supporter

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    :lurk
    larryboy likes this.
  12. Nixels

    Nixels Face fears - live life

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    :scratch Uh, @larryboy – I think you need to uh, you know... Reconsider some of your build choices?

    The N.A.P.A.L.M. bike is for someone else. :nod

    NOT the Dirtbag Challenge.

    [​IMG]

    :fpalm
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  13. larryboy

    larryboy Just obey!

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    Cut out the tube that the little short street shock bolts to.

    IMG_20210324_164421533.jpg


    Figuring things out...

    IMG_20210324_164826192_HDR.jpg
    IMG_20210324_164830989_HDR.jpg IMG_20210324_181323440.jpg IMG_20210324_181327689.jpg


    I'm setting the swingarm angle at 15°. In pictures I find of the CRF250L the dog bones are at about the same angle.

    I'll tack things in, then I'll remove the spring so I can cycle everything to make sure it works.

    I'll have to build an engine mount off the new crosstube since the tube I cut out had an engine mount on it.
    KidKawie, oldbmw, JagLite and 8 others like this.
  14. Barron

    Barron M0DAH0LIC

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    This is an awesome product you are working on, and you're doing a great job documenting it. From one guy who's limited by medical conditions to another, you sir are an inspiration. Thank you.

    -Barron
    oldbmw, JagLite, Nixels and 1 other person like this.
  15. larryboy

    larryboy Just obey!

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    I got the motor mount cut out of the old tube, trimmed, flipped over and bolted in place.

    IMG_20210403_170418602.jpg


    Got my center tube made up.

    IMG_20210403_213841673.jpg


    I need to order a new shaft for my tubing notcher, it's worn out and I ruined two hole saws with it. I get the hole saws warrantied for free if I can get the Matco truck to show up.

    I have to do some Easter things tomorrow, but I think I'll have time to get the dog bone tabs mocked up.
  16. larryboy

    larryboy Just obey!

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    This coolant pipe is just in the way. I realized it's a steel tube pressed into aluminum. Spun it around 180° and opened up some space.

    IMG_20210404_163457588.jpg
  17. Bigbore4

    Bigbore4 Long timer

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    Ya might hit that with a bit of the green wicking Loctite. Don't recall the number, maybe 609? Generally intended for sealing weld porosities, but it usually works well for pressed in tubes and similar.
    greasyfatman, Nixels and larryboy like this.
  18. Nixels

    Nixels Face fears - live life

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    Progress! :happay
    larryboy likes this.
  19. larryboy

    larryboy Just obey!

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    Still waiting for the new tube notcher shaft, tracking says it will arrive tomorrow. Things are taking a long time to arrive.


    Meanwhile...

    Things are a disaster at church, so I got them to buy a new mower and we've gotten the grounds whipped into shape.

    IMG_20210417_123649714.jpg
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  20. larryboy

    larryboy Just obey!

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    Yay!! IMG_20210420_112838223.jpg

    Ordered a couple hole saws from the tool truck, I don't need those sizes to jump back in. I'm trying to push the mowing off on another guy. I'm trying to devote a full day to the build on Saturday.
    dave6253, Nixels, Pezz_gs and 7 others like this.