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

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

  1. Nixels

    Nixels Face fears - live life

    Joined:
    Sep 24, 2006
    Oddometer:
    10,474
    Location:
    HayWeird, CA
    That's what I like about your builds @larryboy - keeping it simple and illustrating what you're posting. :deal

    :zilla
    Pezz_gs, oldbmw and larryboy like this.
  2. bk brkr baker

    bk brkr baker Long timer Supporter

    Joined:
    Jul 19, 2006
    Oddometer:
    12,145
    Location:
    The Bluegrass
    Happy that you're healthy and welding stuff up . Continue please !
    Roadracer_Al, Ladybug and Nixels like this.
  3. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
    Oddometer:
    2,734
    Location:
    Oakland, CA
    Dang! You need to install a grease nipple on that notcher.
  4. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    It has one, I spray dry graphite on it. I hate grease all over everything.

    Made some good progress today.

    IMG_20210521_160410461_HDR.jpg


    Messed up the angle on the forward notch on this tube. Good enough to tape up there so I can see how it looks.

    IMG_20210521_170158226_HDR.jpg


    The frame jig is invaluable for notching because you always know where 0° and 90° are at.

    That's better.

    IMG_20210521_180512786_HDR.jpg


    Got the other side made up. This is the side that will get the tube clamps so the valve cover can be removed.

    IMG_20210521_183148354_HDR.jpg


    Got tempted to pull it out of the jig to put suspension and wheels on it.

    IMG_20210521_184056977_HDR.jpg


    Better get the upper engine mounts in first. Got an original frame tube out to see what Honda did. For some reason the hole for the bolt is way oversized, probably due to variances in each frame.

    IMG_20210521_184921724_HDR.jpg


    Made up a tab for the left side and welded it in. This is what I came up with for the other side.

    IMG_20210521_193114659_HDR.jpg
    Pezz_gs, shinyribs, dave6253 and 10 others like this.
  5. Nixels

    Nixels Face fears - live life

    Joined:
    Sep 24, 2006
    Oddometer:
    10,474
    Location:
    HayWeird, CA
    Wow! You really turned it up a notch, @larryboy.

    :zilla
  6. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    I'm coping well with your posts.

    :drums
  7. Nixels

    Nixels Face fears - live life

    Joined:
    Sep 24, 2006
    Oddometer:
    10,474
    Location:
    HayWeird, CA
    There’s always a way to frame it without tacking on unnecessary words.
  8. oldbmw

    oldbmw havehandlebarswillrideit

    Joined:
    Feb 2, 2008
    Oddometer:
    576
    Location:
    Reedley, CA
    Super exciting!
    Nixels and larryboy like this.
  9. HardWorkingDog

    HardWorkingDog Super Ordinary

    Joined:
    Aug 20, 2009
    Oddometer:
    4,222
    Location:
    Walnut Crick, Cal.
    You mind telling/showing more about your frame jig? Is it something you made, or bought?
    larryboy likes this.
  10. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    It's a kit from Chop Source.

    IMG_20210523_173807442.jpg


    Extra cost for the rotisserie, it's super nice for final welding.

    IMG_20210523_173813638_HDR.jpg


    Extra cost for the feet you can adjust to level out the whole jig.

    IMG_20210523_173820164_HDR.jpg


    All of the tubing is provided by you, so you can make it whatever length or height that you want.
    JagLite, mentolio, Hanz and 4 others like this.
  11. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    Got approval to trap the valve cover in there. I'll use the tube clamps for the cradle.

    So relieved!! :clap

    When I remove the engine to paint the frame I'll check the valves. It's a Honda...
    dwdantzler, dave6253, Barron and 2 others like this.
  12. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    Got her out of the jig and the trees on. Need to check turning radius before final welding.

    IMG_20210626_172003889_HDR.jpg


    Looks like it'll work.

    IMG_20210626_172011277.jpg

    IMG_20210626_173326991_HDR.jpg


    Got things mocked up. No weight on the ground.

    IMG_20210626_174831341_HDR.jpg


    Seat is at 34" there, but no sag, so it can really go up a few inches.

    IMG_20210626_175153639_HDR.jpg


    The total package is tiny, this thing is going to be great!!

    Had big plans for today, couldn't make it happen.
  13. 2on2off

    2on2off Head'n somewhere new

    Joined:
    May 22, 2007
    Oddometer:
    2,314
    Location:
    The Western USA
    This bike is coming together very nicely.
    Vrode, waylongway and larryboy like this.
  14. jays100

    jays100 Been here awhile

    Joined:
    Aug 1, 2006
    Oddometer:
    566
    Location:
    CT
    Are you going to run a loop around the engine from the top rear to the front? I wouldn’t jump this thing otherwise. It appears all stress is concentrated in the tube above the swingarm pivot…a structural hinge point. Or, do you think the cases are strong enough to handle off road duty?

    envisioned loop is horizontal each side so engine still drops out the bottom, ala Harris frames. Not a cradle setup.
    loganlexow likes this.
  15. jays100

    jays100 Been here awhile

    Joined:
    Aug 1, 2006
    Oddometer:
    566
    Location:
    CT
    My chief engineer would say “show me your numbers” but if you say so…
    loganlexow likes this.
  16. 2on2off

    2on2off Head'n somewhere new

    Joined:
    May 22, 2007
    Oddometer:
    2,314
    Location:
    The Western USA
    Great to see the work you are doing. Question: I know there were some issues mounting a skid plate on the CB500X models as the engine is a stress member, I think that is correct. I believe some have said engine bolts could sheer off with a strong enough hit to a skid plate mounted to the engine. 1. Will a skid plate be able to be mounted differently on this bike than a CB500X? 2. Any idea how many inches of increased ground clearance you will have vs. a CB500X?

    I may be getting ahead of myself with these questions since this is still in process. It is fun to watch the progress on this bike.
  17. larryboy

    larryboy Just obey!

    Joined:
    Jan 9, 2005
    Oddometer:
    31,047
    Location:
    Über Alles,California
    @2on2off , I'm building a removable lower cradle that will have a skid plate. We're at 14" of ground clearance unsagged, shooting for 12" at sag.My goal is to have full oil capacity and the cat in place.
    JagLite, Nixels, TimmyTheHog and 2 others like this.
  18. svo_jon

    svo_jon Been here awhile

    Joined:
    May 10, 2019
    Oddometer:
    231
    Location:
    Bend OR
    My rally raid engine guard has taken some good hits without any sheered bolts.

    20201206_122543.jpg



    20201206_133425.jpg

    20201206_122600.jpg

    Jonathan
    SlowernOlder and loganlexow like this.
  19. jays100

    jays100 Been here awhile

    Joined:
    Aug 1, 2006
    Oddometer:
    566
    Location:
    CT
    This is serious, and needs to be thought through more fully.

    The elasticity modulus is the same for both mild steel and chrome moly so nothing is gained by change in material. The difference in tensile strength doesn’t help with the applied load direction. Also, the bend stress on a dirt bike off of a jump is (in engineering parlance) both ends restrained with middle unrestrained…wheels landing with the engine and rider continuing to move. A wheelie (from your pic) is front wheel only, only 1/2 the realized load on that middle frame pipe.

    I can only stress in the strongest possible terms (as an engineer) to rethink adding either a circular stressed link to the down tube or add a cradle underneath the engine. I guess you could restrict riding envelope.
  20. tobiism

    tobiism Long timer Supporter

    Joined:
    Jun 28, 2011
    Oddometer:
    2,253
    Location:
    Chandler AZ
    Screenshot_20210703-145458_Chrome.jpg like this?