TRX954RR build

[siderbox]

Well winter is here. Time for a new project. How bout a TRX954RR.

I'm a 250R junkie. With that said. I don't think the other two sites I frequent would enjoy this thing as you guys would.

I have a CR500 in a JP TRX now that is fun but I'm looking for more.
Have the day time duner for play. The night time duner with some big ***** lights.
Now it's time for some more speed.
At first I was going to mod the JP frame to exepct a 954 engine.

But two problems:
1 Is the hight difference in the frame and engine. Which can be fixed with some cut and reweld leading to the second.
2 I don't really want to cut up a perfectly good JP frame. I have enought spare parts to build another nice night rider.

So I decided to build a frame.
Here are some of the first versions of my vision.

When done I want it to look like a TRX250R with a monster in it.
It'll keep the front suspension with a few upgrades, factory plastic, seat, and such.

Highlights of the over all plan:
Stretch the noise 10 to 12 inches.
1 x .095 or .065 4130 main tubes.
3/4 x .065 or .058 4130 supports.
+8 or +10 inch swinger.
1 x .095 for the swinger.
Swinger mount, 954RR bearings in 2 x .250 turned to except the bearings and seals.
520 chain, 15/56ish sprockets.
I have a set of 24" 14 paddles from the 500.
4 single or 2 dual inlet K&Ns.
Bent tube mounted to the throttle bodies to locate the K&Ns in the area behind the cylinders.
Factory header, modded mid pipe, and a Two Brothers.

http://i53.tinypic.com/121bt5w.jpg
http://i56.tinypic.com/14wpzl5.jpg
This are just some first rough drafts.
I've started to bend some mock up tubes last week.
After the holidays I should have some time to see what fits and what doesn't.

I'm open to ideas and suggestions. Looking for a name for this thing too.

[250x_kyle]

man i love builds like this. looken good. i started a solid works drawing for a buggy but havent had time to work on it. keep us updated. :D

[jcs003]

this should be interesting. it sure wont be a sleeper with the big motor in it but will definitly be cool.

[siderbox]

A few crappy cell phone pics.


http://i54.tinypic.com/2najxiv.jpg
http://i55.tinypic.com/2llk64y.jpg
http://i55.tinypic.com/2znwtxv.jpg
http://i54.tinypic.com/11reptf.jpg
http://i53.tinypic.com/15pihr5.jpg


I'm still in the mock up stage. Made several revisions.

http://i52.tinypic.com/33kvplh.jpg

On my 5th set of upper bars now. Sure glad this tube's 85 cents a foot instead of $4.85 a foot.
Getting ready for the 6th set.

[jd450mx]

What program is that you are using on the computer to layout the frame? Also where can it be purchased? Build looks good!

[siderbox]

Bend Tech PRO is what I'm using. It's very user friendly compared to SolidWorks and the such.
http://www.2020softwaresolutions.com/products.htm
There's a 12 min screen shot video. Well worth the time to watch.
There is also a site with a ton of info on the software, benders, and dang near anything to do with fab.
http://www.offroadfabnet.com/

[troybilt]

Sider that's looking awesome!! Nice build so far, hopefully I'll see you running that beast down at Waynoka in the not so distant future!!!

[siderbox]

Thanks TB.
Plan is to have it done for the Spring trip. Keeping my fingers crossed.

Here's some more pics.
This are of the final lower section, fully welded 4130. Plan on having the arm tabs done by mid week.

http://i51.tinypic.com/xmjvhe.jpg

http://i53.tinypic.com/110j57a.jpg

http://i51.tinypic.com/r8gy0n.jpg

[wannaride4]

Its looking pretty damn cool. This is the type of fire breathing monstor I would love to owen and ride. and what better spot then at St. Anthony ID. Seen lots of monstors there (mainly turboed 700 raptors) but they dont seem reliable, you dont see them out running the dunes, only being towed to and from thunder mt.

[jd450mx]

Originally posted by siderbox
Bend Tech PRO is what I'm using. It's very user friendly compared to SolidWorks and the such.
http://www.2020softwaresolutions.com/products.htm
There's a 12 min screen shot video. Well worth the time to watch.
There is also a site with a ton of info on the software, benders, and dang near anything to do with fab.
http://www.offroadfabnet.com/

Thanks man I'll check it out.

[audioworks04]

from the kc mo area? When you heading down to waynoka this year?

[82toyota]

when???????

[siderbox]

wannaride4
St. Anthony is on the top of the list of places to go for our group. Only problem is the 24 hour drive. So It will have to be a week long trip. Trying to get 4 guys and there families and schedules has been nightmare to get together.

audioworks04
I'm in Gardner, grew up in Blue Springs.
Next trip for me is end of May. 20th I think.

[wannaride4]

Make a post when you plan on getting there. We try and get there a cpl times a year, and its only a 4 or 5 hr drive for us. Just that we got some great riding so close to town, is what makes it so hard to travel very far...

[siderbox]

Got a some more done.
http://i52.tinypic.com/20539eh.jpg
http://i53.tinypic.com/aak7ec.jpg
http://i54.tinypic.com/2eq418w.jpg

[siderbox]

http://i56.tinypic.com/259dbgl.jpg
http://i53.tinypic.com/2j14c5x.jpg

[250x_kyle]

looken good.

[RATPACK Z400]

Looken good ! now all you needs alot of gussets for all the power your putting in frame! awesome design by the way! By the way how much you think in money/time it took you to build this frame?

[Langbolt]

Hey Siderbox,

What are you using to bend the Chromoly Tubing ?

Looks very proffesional!

Did you fabricate the A-Arm tabs ? Or buy them ?

I bought a set from LoneStar....for when I plan on re-doing my HYBRID chassis.

Just need to find a place to bend & weld Chromoly.

Keep up the great work and keep us posted on the progress

:devil:

[siderbox]

Thanks, glad you all like it. It should be fun.

Let me see if I get all these answers.

Langbolt
-Any good tubing bender will work. The stuff from HarborFright and such will not work.
Some money will have to be spent. But You can get a horizontal bender and a die for around 500 dollars. They seem to take more room to use then the verticals.
I have have the Probender 4 from http://www.probender.com/
-I made this arm tabs from cromo flat stock. I called LoneStar to buy some. But they said they did not sell them.
I would have much rather used them.
Do you have a part number or the person you talked to?

RATPACK Z400
-Trust me there's more tube and gussets going in this thing. :cool:
I know it doesn't show in the prints now.

I've gone throw alot of tube trying to get it just the way I want it.
Damn good thing HERW is cheaper then 4130

[Langbolt]

Siderbox,

I was looking at the Horizontal bender from Pro Tools...the 105 to be exact....but I agree they take up space and have to be mounted to the concrete floor....I think I'm heading in the direction you took with the Vertical unit. Too bad you weren't closer, I'd have ya bend some tubing for me and help pay off your bender :D

I guess you spoke to the wrong person at Lonestar.

Try Bobby Boyer Sales associate

1-800-457-7223 ext. 202

contact@lsracing.com

FAX 480-834-2987

Part #'s are:

75-CHA026 - A-ARM MOUNTING TAB, LEFT,CHASSIS

75-CHA027 - A-ARM MOUNTING TAB, RIGHT,CHASSIS

[siderbox]

Man, that would have saved me a ton of time.
Thanks for the numbers and contact.
I've tried there email many times from more than a few computers, always come back 'undeliverable'.
I'm sure I'll be building another frame or two next off season.

The 'mounted to the floor' is the biggest reason I went with the vertical.
It's on wheels. I can roll it any where in the garage or even out to the drive way if needed.
It doesn't have to be completely level, just need to make adjustments with the level.
Another think I like is a degree wheel is not needed. A digital level works like a charm.

Your not that far. Just a day and a half drive. :rolleyes:

[exrider23]

Nice build man! Are you going to make the a arms as well? if so are they mainly 1" OD x .095 wall ?

[siderbox]

Thanks.

Making arms is on the list but is going to wait till after it's running or maybe the next build.
My plan is to use 1x065 for the lowers and .75x065 for the uppers.
For the swinger I'll be using 1x095.

Working on the motor mounts now. The rears are about done.
Have a few ideas for the fronts that I'm going to have to work through.

[rollie]

wow, i was expecting this to be another street bike engine shoved in a hacked up quad frame.

I love watching how the frame is coming together, that is some serious skill to build what your building, can't wait to see it done!

[siderbox]

Thanks but not sure about skill, just not afraid :devil:

Here's a few more pics

Gota love tubing nothcers
http://i56.tinypic.com/v5fjie.jpg

http://i52.tinypic.com/33dfspd.jpg
http://i53.tinypic.com/2us8i3d.jpg

Rear motor mount work
http://i54.tinypic.com/i42s6r.jpg
http://i53.tinypic.com/2jcvxn4.jpg

[siderbox]

Alot of work going on, just doesn't look like it.
Baseball season has started and with three boys playing, it's going to take up some of the fab time.

http://i52.tinypic.com/29nz6tg.jpg
http://i54.tinypic.com/egdb3d.jpg
http://i51.tinypic.com/xe4v2h.jpg

The tape will end up being another tube.

http://i51.tinypic.com/30m65v8.jpg


I'm beginning to think I'm not going to make the May trip with this ride.

[Kovatch]

Looks awesome! Glad to see there are some atv fabbers out there. Best of luck.

[wannaride4]

Very impressive

[Langbolt]

Any Progress ?

Dyin' to see it all together & runnin'.....

:devil:

[siderbox]

No real progress.

Working on the design of the swingarm and mount.

Guess this is going to be more of a winter project :rolleyes:

[Hasteloy-X]

You must weld for a living. Some nice welds there.

What process did you use on this bike? Tig, Mig, or O/A (oxy/acetylene)?

[siderbox]

Thanks -X
It's all been tig.


Plan on getting back on it here in a few weeks now that I've got the 56 back on the road.
This winter's plan is to spend time on both the quad and the Bronco. I'd like to take both of them to the sand next year.

[siderbox]

Looking for a little input. This is the first draft I did last night.
I haven't been able to show the shock mount.
Image there is a two vertical pieces that will tie the three cross bars together and provide the lower shock eye mount.
http://i40.tinypic.com/rrl5bt.jpg
http://i40.tinypic.com/2ey9g0g.jpg
http://i43.tinypic.com/bf2ff5.jpg
http://i44.tinypic.com/25henhh.jpg
http://i39.tinypic.com/1z3v813.jpg

[troybilt]

Nice swingarm design!

I use Bendtech Pro myself. Works great.

[siderbox]

After a few revisions and a few mulligans.
The swing arm is almost done.
Still on the todo list is the shock mount.
A few shots of the extendo swimgarm bolt.
http://i42.tinypic.com/4vikci.jpg
http://i41.tinypic.com/34hdqc6.jpg
http://i40.tinypic.com/23r1kds.jpg
http://i43.tinypic.com/jzy6h3.jpg

[siderbox]

The start of the jig.
http://i41.tinypic.com/98vza9.jpg
http://i39.tinypic.com/30lihx1.jpg
http://i44.tinypic.com/2myq2it.jpg
http://i44.tinypic.com/5ceird.jpg

[siderbox]

A few of the arm.
Still need to do the shock mount.
http://i44.tinypic.com/34t4lg7.jpg
http://i41.tinypic.com/2hqfol2.jpg
http://i41.tinypic.com/28hg0ue.jpg
Excuses the mess. It was getting late and I was tired.

[siderbox]

Some front motor mount work.


http://i44.tinypic.com/sm6n1h.jpg
http://i40.tinypic.com/2czw9g.jpg
http://i44.tinypic.com/rvbw5f.jpg
http://i39.tinypic.com/6ehtgp.jpg
http://i42.tinypic.com/358ccpy.jpg

[siderbox]

Almost done with the swingarm.

http://i43.tinypic.com/2cf8kk1.jpg
http://i39.tinypic.com/w00zo3.jpg
http://i41.tinypic.com/ejwoqu.jpg
http://i42.tinypic.com/1zxlatd.jpg
http://i42.tinypic.com/5a5bex.jpg

[mkh155]

nice work man...thats a well deserved milly lite :macho

[siderbox]

Winter is here. Time to get back to work.
Got a few things burn in that where tacked.

Frame is done for the most part.
Todo short list
Steering stem, bell crank, and mount for both.
Radiator mount.
Rear sub frame.
Fuel tank.
Body work mounts.
Wiring and battery mount.
Air plenum and cleaner mount.

Ok. It's not so short.

http://i48.tinypic.com/21j0g8i.jpg
http://i45.tinypic.com/j5kze8.jpg
http://i46.tinypic.com/2yxogb7.jpg
http://i47.tinypic.com/2e3r729.jpg
http://i48.tinypic.com/xf4zzr.jpg

[Big Red Hammer]

This build is sweet

[ytman]

I just went back over this thread. You are sooooooo close. This is a very ambitious project. Well done(almost). I want to see this thing throw some sand. I'm sure you do too.

[jerorski]

Awesome job, that thing is going to be sick!

[siderbox]

Originally posted by ytman
I just went back over this thread. You are sooooooo close. This is a very ambitious project. Well done(almost). I want to see this thing throw some sand. I'm sure you do too.
I think I'm close, until I lay awake at night thinking of all the things I still need to get done.

The steering linkage and stem is coming along.
Hope to have more pics after this weekend.

[426kidz]

is this where the stem is going to make its home??:macho

[siderbox]

Yep. Well maybe. The top part anyway.

I'm going to see what I can do making a 'drag style' bar.
If I don't like that then the it'll be the anti-vibe set up.

[426kidz]

cool! ill ship it out tomorrow i cut it right down the middle

[siderbox]

She's a roller.
First time the sunlight has touched her.

http://i46.tinypic.com/m7tfdl.jpg

http://i48.tinypic.com/71py88.jpg

http://i47.tinypic.com/2zrq2dx.jpg

[siderbox]

http://i47.tinypic.com/acr4so.jpg

http://i50.tinypic.com/2mg0208.jpg

http://i50.tinypic.com/ojo4so.jpg

[426kidz]

NICE!

[siderbox]

It's been awhile but there has been a 'little' progress.
The main part of the steering linkage is done.
Just need to make the tie rods and the handle bars.


Here are some of the pics of the bell crank for the front section.
http://i44.tinypic.com/5cby2e.jpg
http://i41.tinypic.com/ibz9y8.jpg

As it started.
http://i41.tinypic.com/11h8954.jpg
http://i44.tinypic.com/2emg6xh.jpg

[siderbox]

Had to section the support in order to get the bell crank on and off.
http://i43.tinypic.com/1zf0jyd.jpg
http://i39.tinypic.com/bgpo41.jpg
http://i39.tinypic.com/6ftxt5.jpg
http://i41.tinypic.com/15xllyw.jpg

[siderbox]

Using oilite for upper and lower thrust bearings and three .750 flat caged roller bearings for lateral movement.
http://i39.tinypic.com/1xxdht.jpg
http://i39.tinypic.com/bdwtvd.jpg

[siderbox]

http://i40.tinypic.com/2wriwyf.jpg
http://i40.tinypic.com/34rcgaa.jpg
http://i41.tinypic.com/ibz9y8.jpg
http://i42.tinypic.com/sc9n5t.jpg

[danhung11]

Good progress buddy, keep it up! Hope to see it in the fall?

[skank21]

Awesome fab work!

[400cc]

did this ever get finished?

[siderbox]

Not yet.
We moved in December, with all the prep time to move, the move, and all the post move crap I've had no time to work on it.
Plan is this winter to get back on it.

[siderbox]

Can't believe it's been almost 5 years, the last time I touched this quad.
This winter the time has been set aside to work on finishing it up.

[honda400ex2003]

sounds like an awesome build, hopefully you can get it finished up after all these years.

share some pics!
steve