DR 650 project: It's now a Beast!

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

  1. LukasM

    LukasM Long timer

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    Let me congratulate you on the impressive size your cojones must have Señor Joe. :eek1 I love the angle grinder as much as the next guy but mine hasn't cut off anything structural yet.

    Are you planning on hauling around any luggage? I would guess that the DRZ frame should be reinforced for that, albeit being aluminum it will still be much lighter.

    :clap
  2. DRjoe

    DRjoe Long timer

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    I will be using it to haul luggage. The drz boys don't seem to have any problem carrying stuff on the back but yes i will still add some reinforcing.

    It all looked so easy in my head but now that its on the bike it is going to be a fair bit of work making neat and strong mounting points on the frame.

    I haven't welded steel for a long time so i hope i haven't forgotten how to do it.
  3. dylandr

    dylandr Been here awhile

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    you got balls mate! Would never think of doing something like that! Question... Why not use the drz complete frame with trips shocks and all and build the 650 motor into that? Sure that would still be a challenge and be a kick ass build? Silly question. Sorry. I'll shut up now. Show us more! Loving it!
  4. DRjoe

    DRjoe Long timer

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    That's a very good question and I'm not very sure how to answer it.

    I'm just going with the flow I never intended to use drz plastics but someone told me they might fit but they didn't even come close so that's what made me think of using the drz subframe.

    I'm sure the 650 motor would be harder to fit to the drz than fitting the odd drz part to the dr.(well thats my excuse)
  5. dylandr

    dylandr Been here awhile

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    :thumb good excuse... glued in place... waiting for your every move!
    I really dig this thread! Don't stop!

    :lurk :lurk :lurk :lurk :lurk
  6. DRjoe

    DRjoe Long timer

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    I'll try not to let you down.
    more updates at the weekend.
  7. NOSIGN

    NOSIGN Adventurer

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    :eek1 FARk YEAH! :clap That chop was hardcore! Lovin it! :clap :clap :clap

    ... and i thought the wire brush was the beez neez!
  8. DRjoe

    DRjoe Long timer

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    I forgot to get the metal to make the subframe mounts so i didn't really get much done this weekend.

    I did manage to cut off what was left of the old subframe and give the area a clean up.

    Here's some pics.

    Did you ever do something and then regret doing it.
    [​IMG]

    There's not a lot of meat there.
    [​IMG]

    There is a little bit reinforcing on the inside. There is a small amount of surface rust on the inside of the frame.
    [​IMG]

    The top frame sections have a fair bit of rust in them not bad seeing as the frame is 12 years old.
    [​IMG]


    I got the head and barrel back from the machine shop yesterday.
    They skimmed 1mm (I told him 0.8 but he forgot) off the head and a tiny bit of the barrel they also did a three angle valve job and bead blasted both the barrel and head.

    Very clean
    [​IMG]

    A before and after.
    [​IMG]

    I was thinking of painting the engine black. what do you think of that idea would it look good or bad?

    That's all for now folks.
    Maybe if your good girls and boys i'll do some more work during the week and post some pics.
  9. ADV8

    ADV8 Long timer

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    Sorry i forgot about this until i just read your update.

    Squish or squish clearance is the measurement from the outer band of the piston to the cylinder head at TDC.
    It is generally way over 1mm on stock engines,reducing it to around 1mm,maybe 0.9mm with a titanium con rod will improve general performance.
    It is normally done by measuring with compressible media (hollow solder / blue tack etc) at TDC then as needed removing material off the base of the cylinder using a lathe face plate and mandrel.
    I see your shop machined your cylinder that will change the squish clearance but by how much ?
  10. DRjoe

    DRjoe Long timer

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    Cheers for the explanation mate but I'm afraid that it went strieght over my head though.

    They took 0.1mm of the barrel.
    I was planning on fine tuning the compression ratio using different thickness base gaskets. Would this be still ok to do or is it better to change the head gasket thickness?

    Thanks

    Joe

  11. Brendan J

    Brendan J Pfft

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    Joe I'd be a bit worried that they have taken off so much metal. When I had performance work done to my engine they didn't skim the head or barrel but took one layer out of the head gasket to make the squish clearance better. I was told if 2 out of the 3 layers were taken out I would end up having problems with clearance. Now this would differ with every engine so doing a dry run to check piston to head clearance is going to be adviseable. Mandatory if your running a high comp piston.
  12. DRjoe

    DRjoe Long timer

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    The clearances should still be ok but I will fit it all together and then check the clearances. I will alter them with thicker gaskets if needed.


  13. atsoc82

    atsoc82 Adventurer

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    Hi mate
    Its all looking very shmick and pro. I could see a new job in custom DR's:wink: . Hows the faring coming along.
    Cheers chris.
  14. DRjoe

    DRjoe Long timer

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    "Shmick and pro" you have got to be kidding.

    I'm taking the easy way out with the fairing and getting it from CPW in WA.
    so all i have to do is alter the sides to fit. its been ordered so its just a mater of time.
  15. DRjoe

    DRjoe Long timer

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    I better tidy the work shop then.
  16. atgreg

    atgreg Africatwinarama

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    any updates ???
  17. DRjoe

    DRjoe Long timer

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    sorry not yet I've been kinda busy with work and this dirty old thing

    [​IMG]

    I'll do some more work on it tomorrow.
  18. LukasM

    LukasM Long timer

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    So you are now going to switch to a Safari tank on the DR and adapt the above fairing to it as well, right? :wink:
  19. lamoson

    lamoson something catchier

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    wow, i didn't look at the post, just the picture. i thought THIS was the DR, ha. i was like "DANG, he turned his suzuki into a KTM!!!!!" do they run the exhaust on the left on all ktm's over there?


  20. Mezo

    Mezo Banned

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    Safari did a real good job of that colour match there Joe, you can hardly tell it apart from the factory ORANGE :poser

    Mezo.