gusset my frame today

[B@ckBoneBelgium]

Hello guy's ..

starting to build my machine for next season and started to gusset today before Powdercoating

The Honda stock frame is crap! Great geometry but made from soft steel. MX racing twists this frame causing stress fractures around every weld. Repeat, EVERY! All stock frames that are raced need constant welding. The front shock top mount needs a triangular gusset added at least at the top. The frame tabs for the bolt at the top of the engine will crack on both sides. It actually cracked the top of the engine needing tig repair. It appears that the frame twists in a manner that the bolt pushes upward cracking the tabs. One racer suggests that the bottom of the frame needs a welded reinforcement to keep the motor from pushing upward on the bolt. We have analyzed this and agree. The frame will always eventually crack just to the rear of the foot peg mounts where the frame bends upward. Reinforce this area. This should remain a sacrificial point so as not to bend a more critical non repairable point on the frame. Many of the stock frame welds are poorly filled especially the foot peg attachment points, and need to be filled in for strength.

What do you guys think ? I am still in the process of making it looks nicer with drilling holes in the plate at the steering ...

[B@ckBoneBelgium]

another one

[Sick0]

I think you gusseted to much in the front end.

[B@ckBoneBelgium]

A.O

[B@ckBoneBelgium]

A.O.

[Sick0]

Are you putting anymore gussets on there.

[B@ckBoneBelgium]

It will need to stand trough PARIS DAKAR ....

So it needs to be tough .. Anywhay after jumping in belgium at the mx tracks , i needed a reinforced frame.After doing a search and calling with pro riders , I find out the weak spots in the TRX400 Frame and I reinforced it . I will make the frame not as fmexible as before , but thats life ...

[B@ckBoneBelgium]

forgot one more

[Bean]

mines not twisted yet, but its cracked in 7 places, lol, its getttin some gussets, welding, and painting real soon

[Sparks425Ex]

Man you are a life saver. I cracked my frame in 3 places and i had to bring it in tomarra to get it welded adn i hade no idea where to have them put gussets. Your pics are great.

[B@ckBoneBelgium]

tnx guys ,

for the good comments , adding reinforcement in my subframe soon , will post pics as well ...

greetz

K.

[Extremeracer167]

just buy a new honda frame. Any decent bike shop can sell u one for about 600 bucks! Then gusset and PC it then. The only bad thing about gusseting it that much, is its going to put alot more stress on other areas. Like BETWEEN gussets. and instead of just cracing the welds, the frame will snap on one of the crucial frame rails. I will be getting my new frame here ina few days, and will only be gusseting the front shocks mounts, subframe, and right behind the pegs. That will be plenty. The only place i had any problems with my original frame is right behind the pegs like u said.

[400exRacerX]

Holy crap, You gussetted the crap out of the front end, the frame still needs to flex alittle to handle properly. All I got to say is good luck!

BTW,, you should of stripped the paint before welding gussetts on it. Any welder knows that:o

[beerock]

the bottom gussets you put in ( by the motor mounts)..... you should just take them out and cut a piece of metal to fill in that entire triangled area....

that one gusset by the steering clamp doesnt really look like a good spot... you might want to remove it...

the frame needs to flex a little...

Damn easy guys,,this dude ain't surronded by atvshops and highly knowledgable people like we are here in the states. Sounds like he's tryin to do the best he can with what little he has..:rolleyes:

I agree the frame does need to flex a little though. Should I go ahead and kick him too while hes down???

[B@ckBoneBelgium]

The frame will flex anough ...Do not worry .But indeed , I have to do it with little in Belgium ...But I am well learned and trained by Johhny Simons ....He rides the 12h Pont Du Vaux , etc in the PRo class . The same class as duncan racing and he ain't doing bad ..

Well the welded plate at the steering busshing needs holes in it , before Powder coating ...

[Extremeracer167]

well atleast he took it like a man and didnt get all pissy about it, lol.

[quadman21]

You got it all wrong guys! I saw that frame on episode #58 of the old A-Team sitcom. They built it up like a tank to go shoot up some bad guys....wait a minute...Those x-green berets never hit anything!...lol (sorry, just had to say it)

[B@ckBoneBelgium]

well , continueing in the proces I did some final pic shoots ...

[B@ckBoneBelgium]

next

[B@ckBoneBelgium]

I forsaw the aftermarket A-arms with grease zerks installed on it !

[B@ckBoneBelgium]

bottom welds ,

[B@ckBoneBelgium]

steering stem without greasing it on time !! Now I now I have to grease it very often !!!

[B@ckBoneBelgium]

Could somebody post pics of his subframe that he did for reinforcing it ? I would appriciate it very much tnx

[B@ckBoneBelgium]

BUMP , someone psl ???

[Bean]

i belive Jeff did a 400ex subframe, kenny MIGHT off, mabe norm

[QuadTrix6]

looks good but is it worth all the work on a stock frame i think i would have rather shelled out the bux for an aftermarket frame, but who knows good luck,

beat it till it breaks :devil

[EX 80]

here

[crazy canadian]

thanks for the pics, i'll be doing mine this winter and all the info is much appreciated!

[stocktires]

I think ya did a nice job all by yourself!

Yea, I would have done it a li differently. I just bought a reinforced mint 250r frame with nice PC for $700 shipped.
Then I got it PC'ed and had to get two very small hair-line cracks in the motor mounts re-paired and some welds touched up better (the welds where bad from ECatv) then got fresh high-gloss black PC!
All in all I spent around $1125!!!! I could have a gotten a used Arens for about $1250! I coulda, shoulda, and woulda If I would have known.

more gussetting pics here.. http://www.exriders.com/vbb/showthread.php?s=&threadid=28495