boosted3g build progress

[boosted3g]

Well heres where it all starts. My plans are below and ill try to keep up on the progress pics

http://i231.photobucket.com/albums/ee9/exriders/quadfest055.jpg


04-05 450r engine
13:1 piston and HRC cam
DASA pipe

i want this to look factory and perform like factory built. This is what honda should have built for the XC riders. I hopefully can complete this in 2-3 weeks if i can source all the parts. I thought i had an engine about 5 times this weekend. If anyone is interested i have all the parts on ebay now.

what happened to the xr650 idea? I thought you bought a salvage bike to do it with?

[boosted3g]

I had trouble getting the guy to get in contact with me. I ended up looking at the 450r engine due to its availability. A few items were purchased today ill post progress pics as they come in.

I ended up purchasing the engine i was looking at with the 13:1 piston and the hrc cam so im left with little things now. I also got the oil cooler and lines, the harness with cdi and rectifier. Next of the list to get is a radiator, fan, overflow bottle and motor mounts. Ill try and post when parts come in or when the frame work starts.

[440challenger]

i built that setup about 2 years ago when maybe a few people did it. been running it ever since. frames cracked a bit. if you dont get all the parts dirt cheap its not worth the money and effort. just buy a used 450 for under 3k .

by the way,i was out in lancaster the other day. any good places to rip out there or do the amish get pissed off?

[boosted3g]

The amish get pissed off quick. The cops dont mess around any more and they are impounding them quad on site. Unless you make friends with a farmer your not riding in lancaster. We go to Treverton frequently.

So far everything has been relativly inexpensive to get. I got the radiator fan today and i im looking to get the rest when all my 400 stuff goes off on ebay tommorrow night. Ebay has been good so far and hopefully it continues for these last few things.


Btw did you find any exhaust that goes in with much modifying. I heard the sparks goes in with a slight heat and bend, no chopping.

[440challenger]

All the exhaust work im almost positive. I run the motoworks full system, had a leo vince, and had hrc.

I just made my own rear mount on the sub to fit any 04-05 system. If you need any pics let me know.

[boosted3g]

update, so far i purchased the engine, radiator, fan, all mounts and hoses, shifter pedal, light switch with the hot start and cable, the intake boot, overflow bottle, factory service manual, complete wiring harness with all the electronics, and lots of other little things. Most things i can pick up used very cheap. The only thing i splurged on is a new DASA classic exhaust. Total cost for the built so far after selling my 400 stuff is about 400 bucks and the onloy think that i can think of is oil for the engine and trans and coolant. I was holing to have it running for next weekend but the exhaust is coming from california and wont be here till the following monday unless the UPS comes early.

[boosted3g]

Well the engine is mounted and all the mounts are fabbed except the top one. the radiator and oil cooler and mounted and almost complete also. There are a few things i need to do and hopefully ill get them done tommorrow. The exhaust is requiring some frame modification but nothing too hard. Here the progress so far.

http://i231.photobucket.com/albums/ee9/exriders/hybrid004.jpg

[Bridgewater]

nice progress.
looking good :cool:
keep us up to date

[EX LONERIDER]

definitely looking good. just wondering though, is that radiator and fan just mounted a little too close to the header area? or is it just the camera angle? i cant tell.

Lookin good:cool:

Next time we go to ashland, you should tag along. I wanna see that bad boy in person.:devil:

[boosted3g]

The radiator is close to the fan, its only about 1/4 inch in there but i didnt want to delete it because i do ride slow sometimes. If leter i take it off there is lots of room from the radiator to the header. Thanks for the responses guys, i have some more time to work on it today for a few hours and ill posts pics on the progress. All i need yet it is a rear shock and i expect it to be here monday.

[born2ride14]

to get more room for the rad you could do this.....

[boosted3g]

The radiator will not fit vertical so this is the best available option. I have completed the install with the exhaust and the little things like the coil and overflow tank on. Ill post some pics up tomorrow night with them. I tore everything down and did the last of the final welding so i am tired. I worked about 8 hours on it today and about 6 hours the other day so it took about 14 hours to fit and finish everything. Im going to put everything back in now and run it for a few months and see how everything holds up and then send it off to Pappy to get pc'ed black. Look for pics tomorrow night.

[440challenger]

make sure you gusset that frame its going to crack!
Looking good man, i never had any exhaust clearence or fan clearence problems like your having. What pipe is that?

BTW,wait until you have to take the big clutch cover off one day:eek2: :D

I want to see what you have up your sleeve for the kickstarter

[katch26]

could you use a/two smaller(s) fans run in series instead of the one huge fan in the middle?

[katch26]

or maybe use an "mx" bend headpipe

[boosted3g]

better late than never, enjoy

http://i231.photobucket.com/albums/ee9/exriders/newhybrid002.jpg

http://i231.photobucket.com/albums/ee9/exriders/newhybrid003.jpg

http://i231.photobucket.com/albums/ee9/exriders/newhybrid004.jpg

http://i231.photobucket.com/albums/ee9/exriders/newhybrid001.jpg

[Bridgewater]

looking very nice man.
hows the dasa exhuast on the 400 u know?

[Speedy 400ex]

dang looks nice. Im tempted to do one now.

[honda_runner]

Damn! looks Great! Can't wait to see it done, and in action!

[boosted3g]

Its running and has been on a short test ride till the cops cut it short. It pulls very hard in all the gears and shifts smoothly. Its a little loud but the sound is absolutly incredible. My complaint with first gear being too low in the 400 is cured with 450 gear ratios. You can actually use first gear for something other than creeping along at 2 mph. I rode this back to back with my buddys 08 yzf450 and it feels about the same power but much more nimble. I havent weighed everything but im guessing it is about the same at the 400 maybe slightly lighter but if it is its minimal. All in all with what i sold and what i bought this cost me about 600 bucks and so far its well worth it. Where else are you going to get 400ex handling and 450r power. If you are thinking about doing a swap id suggest it.

[Speedy 400ex]

post up some finished product pics! it love to see them.

[lilyamaharacer4]

[QUOTE]Originally posted by boosted3g
[B]better late than never, enjoy

http://i231.photobucket.com/albums/ee9/exriders/newhybrid004.jpg


I dont think the oil cooler is required anymore, so you might as well take it off.

[400ex28]

Lookin' good man, I plan on doing the same this fall/winter once this race season is over.